Method for manufacturing color filter

ABSTRACT

In the present invention, a provision of a method for manufacturing a color filter capable of forming a highly sophisticated pattern, to be formed easily at a low cost is desired. The present invention achieves the above mentioned object by providing a method for manufacturing a color filter comprising:
     (1) forming a light shielding part on a transparent base material;   (2) forming a wettability changeable layer which the wettability changes by the function of a photocatalyst, on the surface of the transparent base material on the side with the light shielding part formed;   (3) placing the photocatalyst containing layer of the photocatalyst containing layer side substrate which is the photocatalyst containing layer containing a photocatalyst formed on the base member, and the wettability changeable layer with a gap of 200 μm or less, and irradiating an energy from a predetermined direction to form a pixel part forming part comprising a lyophilic area where the contact angle to a liquid is lowered compared with the state before the energy irradiation to the wettability changeable layer, in a pattern; and   (4) coloring the pixel part forming part by the ink jet method so as to form a pixel part.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method for manufacturing a colorfilter suitable for a color liquid crystal display.

2. Description of the Related Art

Recently, accompanied by development of the personal computers, inparticular, development of the portable personal computers, demand tothe liquid crystal displays, particularly color liquid crystal displaystends to be increasing. However, since the color liquid crystal displaysare expensive, cost down is highly requested. In particular, cost downto the color filters, which accounts for a large proportion in terms ofthe cost, is highly requested.

In general, such a color filter comprises coloring patterns of the threeprimary colors including red (R), green (G) and blue (B). The liquidcrystal functions as a shutter by switching electrodes correspondingeach pixel of R, G, and B on or off, thereby light pass through eachpixel of R, G, and B so that the color display is carried out.

As the methods for manufacturing a color filter conventionally executed,for example, a dying method can be presented. In the dying method, acolored pattern is obtained by first forming a water soluble polymermaterial, as the dying material, on a glass substrate, patterning thesame into a desired shape by a photolithography process, and thensoaking the obtained pattern in a dye bath. By repeating the same forthree times, R, G, and B color filter layers are formed.

Moreover, as another method, a pigment dispersion method can bepresented. In the method, a single color pattern is obtained by firstforming a pigment dispersed photo sensitive resin layer on a substrate,and patterning the same. By repeating this process for three times, R,G, and B color filter layers are formed.

As still another method, an electro deposition method, a method ofdispersing a pigment in a thermosetting resin, printing three times forR, G, and B, and thermally curing the resin, or the like can bepresented. However, in any method, the same process should be repeatedfor three times for coloring the three colors of R, C, and B, a problemof a high cost, and a problem of the yield deterioration due to theprocess repetition are involved.

Moreover, a method for manufacturing a pattern formed body, or the like,of forming a pattern using a wettability changeable substance by thefunction of a photocatalyst has been discussed by the present inventors.However, in the methods for manufacturing a pattern formed body by thefunction of a photocatalyst so far, since the photocatalyst is includedin the pattern formed body to be manufactured, a problem of possibilityof being influenced by the photocatalyst, depending on the kind of thepattern formed body, has been involved.

SUMMARY OF THE INVENTION

In view of the above mentioned, provision of a method for manufacturinga color filter, capable of forming a highly sophisticated pattern easilyat a low cost is desired.

The present invention provides a method for manufacturing a color filtercomprising:

(1) forming a light shielding part on a transparent base material;(2) forming a wettability changeable layer, which a wettability changesby a function of a photocatalyst, on a surface of the transparent basematerial on a side which the light shielding part is formed;(3) placing a photocatalyst containing layer of a photocatalystcontaining layer side substrate, which is the photocatalyst containinglayer containing a photocatalyst formed on a base member, and thewettability changeable layer with a gap of 200 μm or less, andirradiating an energy from a predetermined direction to form a pixelpart forming part, in a pattern, comprising a lyophilic area where thecontact angle to a liquid is lowered compared with a state before theenergy irradiation to the wettability changeable layer; and(4) coloring the pixel part forming part by an ink jet method so as toform a pixel part (hereinafter, it is referred to as the firstembodiment).

In this embodiment, since the wettability changeable layer is providedon the transparent base material with the light shielding part formedpreliminarily, and the energy is irradiated after placing thephotocatalyst containing layer side substrate so as to face thewettability changeable layer, only the part where the pixel part isformed can easily be made lyophilic. Therefore, by adhering an ink bythe ink jet method to the pixel part forming part for forming the pixelpart, a pixel part with the ink adhered evenly can be obtained so that acolor filter without color omission or color irregularity can be formed.

Moreover, since the wettability changeable layer does not include aphotocatalyst, the manufactured color filter does not include aphotocatalyst so that an advantage can be provided that no problemderives from the influence of the photocatalyst in any pattern of acolor filter.

In the above mentioned first embodiment, the method may comprise: afteradjusting the wettability changeable layer, placing a photocatalystcontaining layer of a photocatalyst containing layer side substrate,which is the photocatalyst containing layer containing a photocatalystformed on a base member, and the wettability changeable layer with a gapof 200 μm or less, and irradiating an energy from a predetermineddirection to form a liquid repellent convex part forming part, in apattern, comprising a lyophilic area where the contact angle to a liquidis lowered compared with a state before the energy irradiation to thewettability changeable layer of the light shielding part; and forming aliquid repellent convex part on the liquid repellent convex part formingpart.

By accordingly forming an exposing part for the liquid repellent convexpart by irradiating the energy also on the wettability changeable layeron the light shielding part, a lyophilic area for the liquid repellentconvex part forming part can be formed by a predetermined width.Therefore, by coating, or the like, paint for the liquid repellentconvex part on the lyophilic area, the liquid repellent convex parthaving a predetermined width can be obtained by even height. Since theconvex part is liquid repellent, the ink can hardly be moved over theboundary of the pixel part at the time of forming the pixel part, sothat color mixture of the inks or the like can be prevented. Moreover,by contacting the liquid repellent convex part and the photocatalystcontaining layer at the time of the energy irradiation using thephotocatalyst containing layer at the time of forming the pixel part,the liquid repellent convex part can act as a spacer for maintaining acertain gap.

Moreover, the present invention provides a method for manufacturing acolor filter comprising:

(1) forming a wettability changeable layer, which a wettability changesby a function of a photocatalyst, on a transparent base material, on apixel part forming part which is a part on the transparent base materialwhere pixel part is formed;(2) forming a light shielding part on the boundary part of the pixelpart forming part provided with the wettability changeable layer;(3) placing a photocatalyst containing layer of a photocatalystcontaining layer side substrate, which is the photocatalyst containinglayer containing a photocatalyst formed on a base member, and thewettability changeable layer with a gap of 200 μm or less, andirradiating an energy from a predetermined direction to obtain the pixelpart forming part as a lyophilic area where the contact angle to aliquid is lowered compared with a state before the energy irradiation;and(4) coloring the pixel part forming part, provided as a lyophilic area,by an ink jet method so as to form a pixel part (hereinafter, it isreferred to as the second embodiment).

In this case, first the wettability changeable layer is formed in thepixel part forming part, where the pixel part is formed, on thetransparent base material. In the case for example, a material having ahigher contact angle to a liquid, in the state before the energyirradiation, than that of the base material surface is used for thewettability changeable layer, the base material as the light shieldingpart forming part between the pixel part forming part will be alyophilic area having a lower contact angle to a liquid than the pixelpart forming part with the wettability changeable layer formed thereon.In this lyophilic area, for example, the light shielding part can beformed easily with paint for a light shielding part. Then, byirradiating an energy to for example the entire surface with the lightshielding part formed, the pixel part forming part can be provided asthe lyophilic area. Thereby, by coloring the area by the ink jet method,a pixel part with the ink adhered evenly can be obtained so that a colorfilter without color omission or color irregularity can be formed.

Moreover, the present invention provides a method for manufacturing acolor filter comprising:

(1) forming a wettability changeable layer, which a wettability changesby a function of a photocatalyst, on a transparent base material, on alight shielding part forming part which is a part on the transparentbase material where light shielding part is formed;(2) coloring a part on the transparent base material, where thewettability changeable layer is not firmed, by an ink jet method so asto form a pixel part;(3) placing a photocatalyst containing layer of a photocatalystcontaining layer side substrate, which is the photocatalyst containinglayer containing a photocatalyst formed on a base member, and thewettability changeable layer with a gap of 200 μm or less, andirradiating an energy from a predetermined direction to obtain the lightshielding part forming part as a lyophilic area where the contact angleto a liquid is lowered compared with a state before the energyirradiation; and(4) forming a light shielding part in the light shielding part formingpart provided as the lyophilic area (hereinafter, it is referred to asthe third embodiment).

In this case, the wettability changeable layer is formed in the lightshielding part forming part, where the light shielding part is formed,on the color filter substrate. In the case for example, a materialhaving a higher contact angle to a liquid, in the state before theenergy irradiation, than that of the transparent base material surfaceis used for the wettability variable layer, the pixel part forming parttherebetween will be a lyophilic area having a lower contact angle to aliquid than the light shielding part forming part with the wettabilitychangeable layer formed thereon, and the light shielding part formingpart which is the boundary part of the pixel part forming part will be aliquid repellent area. Therefore, in the case an ink is adhered on thepixel part forming part provided as the lyophilic area by the ink jetmethod, the adhered ink can hardly move over the light shielding partforming part which is the liquid repellent area. Therefore, there islittle risk of generating the problem of ink color mixture or the like.By irradiating the energy to the wettability changeable layer of thelight shielding part forming part between the pixel parts afteraccordingly forming the pixel part, the part can be provided as thelyophilic area. Therefore, by coating for example an ink for a lightshielding part on this part, the light shielding part can be formedeasily.

Furthermore, a method for manufacturing a color filter comprising:

(1) placing a wettability changeable layer, which a wettability changesby a function of a photocatalyst, and a photocatalyst containing layerof a photocatalyst containing layer side substrate, which is thephotocatalyst containing layer containing a photocatalyst formed on abase member, with a gap of 200 μm or less, and irradiating an energyfrom a predetermined direction to form the light shielding part formingpart, in a pattern, comprising a lyophilic area where the contact angleto a liquid is lowered compared with a state before the energyirradiation;(2) forming a light shielding part in the light shielding part formingpart provided as the lyophilic area;(3) placing a wettability changeable layer with the light shielding partformed thereon and a photocatalyst containing layer with a gap of 200 μmor less, and irradiating an energy from a predetermined direction toform a pixel part forming part, in a pattern, comprising a lyophilicarea where the contact angle to a liquid is lowered compared with astate before the energy irradiation; and(4) coloring the pixel part forming part provided as the lyophilic areaby the ink jet method, so as to form a pixel part, is provided(hereinafter, it is referred to as the fourth embodiment).

In this embodiment, by using the photocatalyst containing layer sidesubstrate on the wettability changeable layer to provide only the areawhere the light shielding part is formed as the lyophilic area, and thencoating a paint for the light shielding part on this part, the lightshielding part can be formed. Therefore, since the developing process orthe etching process after the pattern exposure, which has been executedconventionally at the time of forming the light shielding part, are notnecessary, the light shielding part can be formed efficiently. Moreover,by irradiating an energy, for example, on the entire surface, the areafor forming the pixel part can easily be provided as the lyophilic area.Therefore, by coloring the part by the ink jet method, a pixel part withthe ink adhered evenly can be provided so that a color filter withoutcolor omission or color irregularity can be formed.

Furthermore, the present invention provides a method for manufacturing acolor filter comprising:

(1) placing a wettability changeable layer, which a wettability changesby a function of a photocatalyst, and a photocatalyst containing layerof a photocatalyst containing layer side substrate, which is thephotocatalyst containing layer containing a photocatalyst formed on abase member, with a gap of 200 μm or less, and irradiating an energyfrom a predetermined direction to form a pixel part forming part, in apattern, comprising a lyophilic area where the contact angle to a liquidis lowered compared with a state before the energy irradiation;(2) forming a pixel part by coloring the pixel part forming partprovided as the lyophilic area by an ink jet method;(3) placing a wettability changeable layer with the pixel part formedthereon and a photocatalyst containing layer with a gap of 200 μm orless, and irradiating an energy from a predetermined direction to form alight shielding part forming part, in a patter, comprising a lyophilicarea where the contact angle to a liquid is lowered compared with astate before the energy irradiation; and(4) forming a light shielding part in the light shielding part formingpart provided as the lyophilic area (hereinafter, it is referred to asthe fifth embodiment).

In this case, first, by irradiating an energy to the above mentionedpixel part forming part of the wettability changeable layer, the pixelpart forming part can be provided as the lyophilic area. Therefore, byadhering an ink to the pixel part forming part by the ink jet method,the ink is spread evenly so as not to generate color irregularity or thelike. Moreover, since the energy is not irradiated to the lightshielding part forming part which is the boundary part to the pixelpart, it remains as the liquid repellent area. Therefore, the inkadhered on the pixel part forming part which is the lyophilic area canhardly be moved beyond the light shielding part forming part which isthe liquid repellent area. Thus, the problem of the ink mixture, or thelike will not be generated. By irradiating the energy to the lightshielding part forming part between the pixel parts after accordinglyforming the pixel part, the part can be provided as the lyophilic area.Therefore, by coating, for example, an ink for the light shielding parton this part, the light shielding part can easily be formed.

In the above mentioned fourth embodiment and fifth embodiment, it ispreferable that the method for manufacturing a color filter according toclaim 5, wherein the wettability changeable layer is formed on thetransparent base material. Since the wettability changeable layer formedof a material which the wettability changeable drastically is generallyof a material hardly having the self supporting property, the strengthor the like is increased by forming on the transparent base material sothat it can be applied to various kinds of color filters.

Furthermore, the present invention provides a method for manufacturing acolor filter comprising:

(1) forming a light shielding part on a wettability changeable layer,which a wettability changes by a function of a photocatalyst;(2) placing a photocatalyst containing layer of a photocatalystcontaining layer side substrate, which is the photocatalyst containinglayer containing a photocatalyst formed on a base member, and thewettability changeable layer with a gap of 200 μm or less, andirradiating an energy from a predetermined direction to form a pixelpart forming part, in a patter, comprising a lyophilic area where thecontact angle to a liquid is lowered compared with a state before theenergy irradiation; and(3) coloring the pixel part forming part provided as the lyophilic areaby the ink jet method so as to form a pixel part (hereinafter, it isreferred to as the sixth embodiment).

In this embodiment, by preliminarily forming the light shielding part onthe wettability changeable layer which the wettability changes by thefunction of a photocatalyst, and irradiating an energy to the pixel partforming part of the wettability changeable layer after placing thephotocatalyst containing layer side substrate, the above mentioned pixelpart forming part can be provided as the lyophilic area. By adhering anink on the pixel part forming part provided as the lyophilic area by theink jet method, a pixel part with the ink adhered evenly can be obtainedso that the ink can be spread evenly without generating colorirregularity or the like.

Moreover, at the time, the above mentioned wettability changeable layermay be formed on the transparent base material. Since the wettabilitychangeable layer formed of a material which the wettability changesdrastically is generally of a material hardly having the self supportingproperty, the strength or the like is increased by forming on thetransparent base material so that it can be applied to various kinds ofcolor filters.

In any of the above mentioned inventions, it is preferable that theprocess of forming the pixel part forming part provided as the lyophilicarea, and coloring the same by the ink jet method to form the pixel partcomprises:

(a) placing a photocatalyst containing layer of a photocatalystcontaining layer side substrate, which is the photocatalyst containinglayer containing a photocatalyst formed on a base member, and thewettability changeable layer with a gap of 200 μm or less, andirradiating an energy from a predetermined direction to form a firstpixel part forming part, in a pattern, comprising a lyophilic area wherethe contact angle to a liquid is lowered compared with a state beforethe energy irradiation;(b) coloring the first pixel part forming part provided as the lyophilicarea by the ink jet method so as to form a first pixel part;(c) placing the photocatalyst containing layer and the wettabilitychangeable layer with a gap of 200 μm or less, and irradiating an energyfrom a predetermined direction to form a second pixel part forming part,in a pattern, comprising a lyophilic area where the contact angle to aliquid is lowered compared with a state before the energy irradiation;and(d) coloring the second pixel part forming part provided as thelyophilic area by the ink jet method so as to form a second pixel part.

In the present invention, for the pixel part formation, the ink iscoated on the pixel part forming part by the ink jet method forcoloring. However, in the case the adjacent pixel part forming parts areclose to each other, the adjacent inks may be mixed at the time ofcoating the ink. Therefore, as mentioned above, according to a method offirst forming the first pixel part and then forming the second pixelpart, for example, at the time of forming the first pixel part, patternexposure can be carried out such that every other pixel part is formedso that the adjacent pixel parts can be provided in a state away fromthe each other at the time of the first time image part formation.Accordingly, by forming the first pixel part forming part in a statewith a relatively wide liquid repellent area provided inbetween theareas to be colored, and coloring the same by the ink jet method, atrouble of the adjacent pixel part ink mixture will not occur. Byirradiating an energy again in between the accordingly formed firstpixel parts to form the second pixel part forming part, and coloring thesame by the ink jet method, a color filter can be formed without thetrouble of the ink mixture or the like.

In any of the above mentioned inventions, it is preferable that thecontact angle, to a liquid having a 40 mN/m surface tension, on thewettability changeable layer is 10° or more on a part without the energyirradiation and it is 9° or less on a part with the energy irradiation.Thereby, the above mentioned wettability changeable layer can be used asthe liquid repellent area before receiving the energy irradiation, andas the lyophilic area after the energy irradiation.

In the above mentioned inventions, it is preferable that the wettabilitychangeable layer is a layer containing an organo polysiloxane. Byforming the wettability changeable layer using the organo polysiloxaneas the material, the wettability changeable layer with a wettabilitypattern, of a large wettability difference, formed can be provided.

Moreover, at the time, it is preferable that the above mentioned organopolysiloxane is a polysiloxane containing a fluoro alkyl group. By usinga polysiloxane containing a fluoro alkyl group, the wettabilitychangeable layer with a larger wettability difference can be provided.

Furthermore, it is preferable that the organopolysiloxane is an organopolysiloxane as a hydrolyzed condensate or a cohydrolyzed condensate ofone kind or two or more kinds of silicon compounds represented byY_(n)SiX_((4-n)) (Here, Y is an alkyl group, a fluoro alkyl group, avinyl group, an amino group, a phenyl group, an epoxy group, or anorganic group containing them, X is an alkoxyl group, or a halogen, andn is an integer from 0 to 3.). By forming the wettability changeablelayer using such organo polysiloxane as the material, a color filterwith a wettability pattern, of a large wettability difference, formedcan be provided.

Moreover, the present invention provides a method for manufacturing acolor filter comprising:

(1) forming a light shielding part on a transparent base material;(2) forming a decomposition removal layer, on the surface of thetransparent base material on the side with the light shielding partformed, having a higher contact angle to a liquid than the transparentbase material surface, and is decomposed and removed by the function ofa photocatalyst;(3) placing a photocatalyst containing layer of a photocatalystcontaining layer side substrate, which is the photocatalyst containinglayer containing a photocatalyst formed on a base member, and thedecomposition removal layer with a gap of 200 μm or less, andirradiating an energy from a predetermined direction to form a pixelpart forming part, in a pattern, comprising the transparent basematerial bared by the decomposition removal of the decomposition removallayer; and(4) coloring the pixel part forming part by the ink jet method so as toform a pixel part (hereinafter, it is referred to as the seventhembodiment).

In this embodiment, since the decomposition removal layer is provided onthe transparent base material with the light shielding part formedpreliminarily, and the energy is irradiated after placing thephotocatalyst containing layer side substrate facing the decompositionremoval layer, the decomposition removal layer of the pixel part formingpart, where the pixel part is formed, can be decomposed and removedeasily. Here, since the above mentioned decomposition removal layer hasa higher contact angle to a liquid compared with the above mentionedtransparent base material surface, the area with the transparent basematerial bared by the decomposition and removal of the decompositionremoval layer can be provided as the lyophilic area, and the area withthe above mentioned decomposition removal layer remaining can beprovided as the liquid repellent area. Therefore, in the case an ink isadhered, by the ink jet method, to the pixel part forming part providedas the lyophilic area, since the adhered ink can hardly be moved overthe liquid repellent area existing in between the pixel part formingparts, a highly sophisticated pattern can be formed with little risk ofgenerating a problem of the ink color mixture or the like. Furthermore,since the pixel part forming part is the lyophilic area, a pixel partwith the ink adhered evenly can be obtained by the ink jet method sothat a color filter without color omission or color irregularity can beformed.

The above mentioned seventh embodiment may comprise, after forming thedecomposition removal layer, placing the photocatalyst containing layerand the decomposition removal layer with a gap of 200 μm or less, andforming a liquid repellent convex part forming part, in a pattern,comprising the bared light shielding part by the decomposition removalof the decomposition removal layer by irradiating an energy from apredetermined direction; and

forming a liquid repellent convex part in the liquid repellent convexpart forming part.

Accordingly, the liquid repellent convex part forming part can be formedby the energy irradiation on the decomposition removal layer on thelight shielding part. Therefore, for example, in the case the contactangles to a liquid of the above mentioned decomposition removal layerand the above mentioned light shielding part differ, the liquidrepellent convex part with a predetermined width and an even height canbe formed easily by coating a paint for the liquid repellent convexpart. Moreover, since the convex part is liquid repellent, the ink canhardly be moved over the boundary of the pixel part at the time offorming the pixel part so that the ink color mixture or the like can beprevented. Moreover, by contacting the liquid repellent convex part andthe photocatalyst containing layer at the time of the energy irradiationusing the photocatalyst containing layer side substrate at the time offorming the pixel part, the liquid repellent convex part can act as aspacer for maintaining a certain gap.

Moreover, the present invention provides a method for manufacturing acolor filter comprising:

(1) forming a decomposition removal layer, on the a transparent basematerial, having a higher contact angle to a liquid than the transparentbase material surface and is decomposed and removed by the function of aphotocatalyst;(2) placing the decomposition remocal layer and a photocatalystcontaining layer of a photocatalyst containing layer side substrate,which is the photocatalyst containing layer containing a photocatalystformed on a base member, with a gap of 200 μm or less, and irradiatingan energy from a predetermined direction to form a light shielding partforming part, in a pattern, comprising the transparent base materialbared by the decomposition removal of the decomposition removal layer;(3) forming a light shielding part in the light shielding part formingpart;(4) placing the decomposition removal layer with the light shieldingpart formed thereon, and the photocatalyst containing layer with a gapof 200 μm or less, and irradiating an energy from a predetermineddirection to form a pixel part forming part, in a pattern, comprisingthe transparent base material bared by the decomposition removal of thedecomposition removal layer; and(5) coloring the pixel part forming part by an ink jet method so as toform a pixel part (hereinafter, it is referred to as the eighthembodiment).

In this embodiment, first, the decomposition removal layer is formed onthe transparent base material. Since the decomposition removal layer hasa higher contact angle to a liquid compared with the above mentionedtransparent base material surface, the area with the transparent basematerial bared by the decomposition and removal of the decompositionremoval layer can be provided as the lyophilic area, and the area withthe above mentioned decomposition removal layer remaining can beprovided as the liquid repellent area. Therefore, the lyophilic areacomprising the transparent base material can be provided by thedecomposition and removal of the decomposition removal layer of thelight shielding part forming part by the energy irradiation using thephotocatalyst containing layer to the light shielding part forming parton the above mentioned transparent base material. Thereby, the lightshielding part can be formed easily by coating an ink for the lightshielding part forming part to the light shielding part forming partprovided as the lyophilic area. Therefore, the developing process or theetching process after energy irradiation which was executedconventionally at the time of forming the light shielding part are notnecessary, the light shielding part can be formed efficiently. Moreover,by irradiating an energy, for example, to the entire surface afterforming the light shielding part, the pixel part forming part lyophilicarea for forming the pixel part can be provided easily. Therefore, bycoloring the part by the ink jet method, a pixel part with the inkadhered evenly can be provided so that a color filter without coloromission or color irregularity can be formed.

Moreover, the present invention provides a method for manufacturing acolor filter comprising:

(1) forming a decomposition removal layer, on the a transparent basematerial, having a higher contact angle to a liquid than the transparentbase material surface and is decomposed and removed by the function of aphotocatalyst;(2) placing the decomposition remocal layer and a photocatalystcontaining layer of a photocatalyst containing layer side substrate,which is the photocatalyst containing layer containing a photocatalystformed on a base member, with a gap of 200 μm or less, and irradiatingan energy from a predetermined direction to form a pixel part formingpart, in a pattern, comprising the transparent base material bared bythe decomposition removal of the decomposition removal layer;(3) coloring the pixel part forming part by the ink jet method so as toform a pixel part;(4) placing the decomposition removal layer with the pixel part formedthereon, and the photocatalyst containing layer with a gap of 200 μm orless, and irradiating an energy from a predetermined direction to form alight shielding part forming part, in a pattern, comprising thetransparent base material bared by the decomposition removal of thedecomposition removal layer; and(5) forming a light shielding part in the light shielding part formingpart (hereinafter, it is referred to as the ninth embodiment).

In this embodiment, first the decomposition removal layer is formed onthe transparent base material. Here, since the above mentioneddecomposition removal layer has a higher contact angle to a liquidcompared with the above mentioned transparent base material surface, thearea with the transparent base material bared by the decomposition andremoval of the decomposition removal layer can be provided as thelyophilic area, and the area with the above mentioned decompositionremoval layer remained can be provided as the liquid repellent area.Therefore, the lyophilic area comprising the transparent base materialcan be provided by the decomposition and removal of the decompositionremoval layer of the pixel part forming part by the energy irradiationusing the photocatalyst containing layer side substrate to the pixelpart forming part on the above mentioned transparent base material. Byadhering an ink on the pixel part forming part provided as the lyophilicarea by the ink jet method, the ink can be spread evenly withoutgenerating color irregularity or the like. Moreover, the light shieldingpart forming part, which is the boundary part to the pixel part, remainsas the liquid repellent area with the decomposition removal layerremaining. Therefore, the ink adhered on the pixel part forming partwhich is the lyophilic area can hardly be moved over the light shieldingpart forming part which is as the liquid repellent area. Therefore, aproblem of the ink color mixture or the like will not be generated. Byirradiating an energy to the light shielding part forming part inbetween the pixel parts after accordingly forming the pixel part, thedecomposition removal layer in this part is decomposed and removed sothat the lyophilic area comprising the transparent base material can beprovided. Therefore, the light shielding part can be formed easily bycoating, for example, an ink for the light shielding part to this area.

In the above mentioned seventh to ninth embodiments, it is preferablethat the process of forming the pixel part forming part where thetransparent base material is bared by the decomposition removal of thedecomposition removal layer, and coloring the same by the ink jet methodto form the pixel part comprises:

(a) placing a photocatalyst containing layer of a photocatalystcontaining layer side substrate, which is the photocatalyst containinglayer containing a photocatalyst formed on a base member, and thedecomposition removal layer with a gap of 200 μm or less, andirradiating an energy from a predetermined direction to form a firstpixel part forming part, in a pattern, comprising the transparent basematerial bared by the decomposition removal of the decomposition removallayer;(b) coloring the first pixel part forming part by the ink jet method soas to form a first pixel part;(c) placing the photocatalyst containing layer and the decompositionremoval layer with a gap of 200 μm or less, and irradiating an energyfrom a predetermined direction to form a second pixel part forming part,in a pattern, comprising the transparent base material bared by thedecomposition removal of the decomposition removal layer; and(d) coloring the second pixel part forming part by the ink jet method soas to form a second pixel part.

In the present invention, for the pixel part formation, the ink iscoated on the pixel part forming part by the ink jet method forcoloring. However, in the case the adjacent pixel part forming parts areclose to each other, the adjacent inks may be mixed at the time ofcoating the ink. Therefore, as mentioned above, according to the methodof first forming the first pixel part and then forming the second pixelpart, for example, at the time of forming the first pixel part, energyirradiation can be carried out in a pattern such that every other firstpixel part is formed so that the adjacent pixel parts can be provided ina state away from the each other at the time of the first time imagepart formation. Accordingly, by forming the first pixel part formingpart in a state with a relatively wide liquid repellent area provided inbetween the areas to be colored, and coloring the same by the ink metmethod, a trouble of the adjacent pixel part ink mixture can beprevented. By irradiating an energy again in between the first pixelparts formed accordingly to form the second pixel parts, and coloringthe same by the ink jet method, a color filter can be formed without thetrouble of the ink mixture or the like.

In the inventions of the above mentioned seventh to ninth embodiments,it is preferable that the contact angle to a liquid on the abovementioned transparent base material, as the contact angle to a liquidhaving a 40 mN/m surface tension, is less than 10 degrees. By having thecontact angle to a liquid, on the transparent base material bared at thetime of the decomposition and removal of the above mentioneddecomposition removal layer by the photocatalyst, of the above mentionedvalue, the bared transparent base material can be provided as thelyophilic area so that the pixel part and the light shielding part canbe formed easier by the ink jet method or the like.

Moreover, at the time, it is preferable that the contact angle to aliquid having a 40 mN/m surface tension on the above mentioneddecomposition removal layer is 100 or more. By having the contact angleto a liquid on the above mentioned decomposition removal layer as theabove mentioned value, it can provided liquid repellently compared withthe base material bared by the decomposition and removal, and thus acolor filter can be manufactured easily.

Moreover, it is preferable that the above mentioned decompositionremoval layer is any of a self-assembled monolayer, a Langmuir Blodgettfilm, or a layer-by layer self-assembled film. These films are easy toform a thin film with, they have a relatively high strength, and theyhave good adhesion to the base material.

Moreover, in the above mentioned first to seventh embodiments, it ispreferable that a width of the pixel part is formed wider than the widthof a opening part formed by the light shielding part. By accordinglyhaving the width of the pixel part wider than the opening part formed bythe light shielding part, the risk, of passage of a backlighting lightbeam through the part other than the pixel part, can be reduced so thatcolor omission or the like can be prevented.

Here, in the present invention, it is preferable that the photocatalystcontaining layer and the wettability changeable layer or thedecomposition removal layer are placed with a gap in a range of 0.2 μmto 10 μm. Since the gap between the photocatalyst containing layer andthe wettability changeable layer or the decomposition removal layer isin the above mentioned range, the wettability change of the wettabilitychangeable layer or the decomposition removal of the decompositionremoval layer can be carried out by the energy irradiation for a shorttime.

Moreover, the above mentioned photocatalyst containing layer sidesubstrate may comprise the base member and the photocatalyst containinglayer formed in a pattern on the above mentioned base member. Byaccordingly forming the photocatalyst containing layer in a pattern, thewettability change of the wettability changeable layer or thedecomposition and removal of the decomposition removal layer can becarried out in a pattern without using a photomask. Moreover, since onlythe wettability of the wettability changeable layer of the color filtersubstrate facing the pattern of the photocatalyst containing layer ischanged, or only the decomposition removal layer is decomposed andremoved, the energy to be irradiated is not particularly limited to aparallel energy, and furthermore, the energy irradiation direction isnot particularly limited, and thus it is advantageous in that the degreeof freedom in the kind of the energy source and the arrangement can beincreased dramatically.

Moreover, the above mentioned photocatalyst containing layer sidesubstrate may comprise a base member, a photocatalyst containing layerformed on the above mentioned base member, and a photocatalystcontaining layer side light shielding part formed in a pattern, whereinthe energy irradiation in the above-mentioned energy irradiating processmay be carried out from the photocatalyst containing layer sidesubstrate. Accordingly, by providing the photocatalyst containing layer,and the photocatalyst containing layer side light shielding part formedin a pattern, in the photocatalyst containing layer side substrate, andirradiating the energy from the side of the photocatalyst containinglayer side substrate, the wettability of the wettability changeablelayer can be changed in a pattern, or the decomposition removal layercan be decomposed and removed in a pattern, without using a photomask.Moreover, since the photomask is not used, a process of aligning or thelike of the photomask is not necessary, and thus the process can besimplified.

The above mentioned photocatalyst containing layer side substrate maycomprise the photocatalyst containing layer formed on the abovementioned base member, and the above mentioned photocatalyst containinglayer side light shielding part formed in a pattern on the abovementioned photocatalyst containing layer. Moreover, the above mentionedphotocatalyst containing layer side substrate may comprise the abovementioned photocatalyst containing layer side light shielding partformed in a pattern on the above mentioned base member, and furthermore,the above mentioned photocatalyst containing layer formed thereon.Thereby, since the pattern formation needs to be executed only on theabove mentioned photocatalyst containing layer side light shielding partso that the above mentioned photocatalyst containing layer can be formedon the entire surface, the entire photocatalyst containing layer sidesubstrate can be formed easily, and thus it is preferable also in termsof the cost, the manufacturing efficiency, or the like.

Moreover, at the time, the above mentioned photocatalyst containinglayer side substrate may comprise the photocatalyst containing layerformed on the photocatalyst containing layer side light shielding partformed in a pattern on the transparent base material via a primer layer.Thereby, influence of the residue or the like, existing on thephotocatalyst containing layer side light shielding part or the openingpart between the photocatalyst containing layer side light shieldingparts generated at the time of patterning the photocatalyst containinglayer side light shielding part, on the function of the photocatalystcan be prevented. Therefore, the sensitivity of the photocatalyst can beimproved so that a pattern of the changed wettability of the wettabilitychangeable layer or a pattern of the decomposed and removeddecomposition removal layer can be obtained by the energy irradiationfor a short time.

According to any of the above mentioned inventions, it is preferablethat a spacer having the thickness in a range of 0.2 μm to 10 μm isformed in a pattern on the photocatalyst containing layer in thephotocatalyst containing layer side substrate, and the energyirradiation is carried out with the spacer and the wettabilitychangeable layer or the decomposition removal layer being in contact.Since the photocatalyst containing layer is covered with the spacer inthe part with the spacer formed, the wettability of the wettabilitychangeable layer of this part is not changed even in the case the energyis irradiated, or the decomposition removal layer is not decomposed andremoved. Therefore, the wettability of the wettability changeable layercan be changed or the decomposition removal layer can be decomposed andremoved in the area other than the pattern of the spacer formed.

Furthermore, it is preferable that the above mentioned spacer is thephotocatalyst containing layer side light shielding part formed with alight shielding material. Since the spacer is the photocatalystcontaining layer side light shielding part, a higher sophisticatedpattern can be formed by irradiating the energy in a state which thephotocatalyst containing layer side light shielding part is closelycontacted to the wettability changeable layer or the decompositionremoval layer.

In the above mentioned inventions, it is preferable that thephotocatalyst containing layer is a layer consisting of a photocatalyst.In the case the photocatalyst containing layer is a layer consisting ofonly a photocatalyst, the efficiency of changing the wettability of thewettability changeable layer or the efficiency of decomposing andremoving the decomposition removal layer can be improved so that a colorfilter can be manufactured efficiently.

In this case, it is preferable that the photocatalyst containing layeris a layer formed by forming a film of a photocatalyst on the basemember by a vacuum film formation method. By forming the photocatalystcontaining layer by the vacuum film formation method, an uniformphotocatalyst containing layer having an even film thickness with littlesurface roughness can be provided so that the wettability change of thewettability changeable layer or the decomposition removal of thedecomposition removal layer can be carried out efficiently.

Moreover, the above mentioned photocatalyst containing layer may be alayer having a photocatalyst and a binder. By using the binderaccordingly, the photocatalyst containing layer can be formed relativelyeasily so that a color filter can be manufactured at a low cost, as aresult.

In the above mentioned inventions, it is preferable that 36. The methodfor manufacturing a color filter according to claim 1, wherein thephotocatalyst is one kind or two or more substances selected from atitanium oxide (TiO₂), a zinc oxide (ZnO), a tin oxide (SnO₂), astrontium titanate (SrTiO₃), tungsten oxide (WO₃), bismuth oxide(Bi₂O₃), and an iron oxide (Fe₂O₃). By having the above mentionedsubstances as the above mentioned photocatalyst, the catalytic reactioncan be executed efficiently. Moreover, among the above mentionedsubstances, it is preferable that the photocatalyst is a titanium oxide(TiO₂) because the band gap energy of a titanium dioxide is high so thatit is effective as a photocatalyst, it is chemically stable without thetoxicity, and it can be obtained easily.

Moreover, the above mentioned energy irradiation may be carried outwhile heating the photocatalyst containing layer. By executing the abovementioned energy irradiation while heating the photocatalyst containinglayer, the effect of the photocatalyst can be improved so that thedecomposition removal layer can be decomposed and removed by energyirradiation for a short time.

In the present invention, it is preferable that the above mentionedlight shielding part is made of a resin. By having the above mentionedlight shielding part made of a resin, it can be formed easily by the wetprocess.

Moreover, the present invention provides a color filter comprising atransparent base material, a pixel part provided on the transparent basematerial in a predetermined pattern with a plurality of colors by an inkjet method, a light shielding part provided on the boundary part of thepixel part, and a decomposition removal layer capable of beingdecomposed and removed by the photocatalyst, provided for forming thepixel part or the light shielding part.

According to the present invention, since the decomposition removallayer capable of being decomposed and removed by the photocatalyst isprovided to form the above mentioned pixel part or the above mentionedlight shielding part, a highly sophisticated pattern can be formed, anda color filter to be manufactured easily can be provided.

Moreover, the present invention provides a color filter comprising atransparent base material, a pixel part provided on the transparent basematerial in a predetermined pattern with a plurality of colors by theink jet method, a light shielding part provided on the boundary part ofthe pixel part, and a decomposition removal layer capable of beingdecomposed and removed by the function of the photocatalyst formed onthe light shielding part. Since the decomposition removal layer, havinga contact angle to a liquid larger than that on the transparent basematerial, is formed on the above mentioned light shielding part, the inkcolor mixture or the like can be prevented at the time of forming acolor filter so that a color filter having a highly sophisticatedpattern can be provided.

The present invention provides a liquid crystal display comprising acolor filter manufactured by any one of the above mentioned method formanufacturing a color filter, a substrate facing the same, and a liquidcrystal compound sealed in between the both substrates. The color filtermanufactured by the above mentioned methods for manufacturing a colorfilter has a highly sophisticated pattern and it is capable of beingmanufactured at a low cost, a highly sophisticated liquid crystaldisplay can be provided at a low cost by using the color filter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A, 1B, 1C, 1D, and 1E are process diagrams for explaining a firstembodiment of a method for manufacturing a color filter according to thepresent invention.

FIGS. 2A and 2B are schematic cross sectional views showing an exampleof a photocatalyst containing layer side substrate used in the presentinvention.

FIG. 3 is a schematic cross sectional view showing another example of aphotocatalyst containing layer side substrate used in the presentinvention.

FIG. 4 is a schematic cross sectional view showing another example of aphotocatalyst containing layer side substrate used in the presentinvention.

FIG. 5 is a schematic cross sectional view showing another example of aphotocatalyst containing layer side substrate used in the presentinvention.

FIG. 6 is a schematic cross sectional view showing another example of aphotocatalyst containing layer side substrate used in the presentinvention.

FIGS. 7A, 7B, 7C, and 7D are schematic diagrams for explaining anotherexample of method for irradiating an energy to a pixel part in themethod for manufacturing a color filter shown in FIGS. 1A, 1B, 1C, 1D,and 1E.

FIGS. 8A, 8B, 8C, 8D, and 8E are process diagrams for explaining amethod for manufacturing a liquid repellent convex part in the methodfor manufacturing a color filter shown in FIGS. 1A, 1B, 1C, 1D and 1E.

FIGS. 9A, 9B, 9C, 9D, and 9E are process diagrams for explaining asecond embodiment of a method for manufacturing a color filter accordingto the present invention.

FIGS. 10A, 10B, 10C, and 10D are process diagrams for explaining a thirdembodiment of a method for manufacturing a color filter according to thepresent invention.

FIGS. 11A, 11B, 11C, 11D, and 11E are process diagrams for explaining afourth embodiment of a method for manufacturing a color filter accordingto the present invention.

FIGS. 12A, 12B, 12C, and 12D are process diagrams for explaining a fifthembodiment of a method for manufacturing a color filter according to thepresent invention.

FIGS. 13A, 13B, 13C, and 13D are process diagrams for explaining a sixthembodiment of a method for manufacturing a color filter according to thepresent invention.

FIGS. 14A, 14B, 14C, 14D, and 14E are process diagrams for explaining aseventh embodiment of a method for manufacturing a color filteraccording to the present invention.

FIGS. 15A, 15B, 15C and 15D are process diagrams for explaining a methodfor manufacturing a liquid repellent convex part in the method formanufacturing a color filter shown in FIGS. 14A, 14B, 14C, 14D, and 14E.

FIGS. 16A, 16B, 16C, 16D, and 16E are schematic diagrams for explaininganother example of method for irradiating an energy to a pixel part inthe method for manufacturing a color filter shown in FIGS. 14A, 14B,14C, 14D, and 14E.

FIGS. 17A, 17B, 17C, 17D, 17E, and 17F are process diagrams forexplaining an eighth embodiment of a method for manufacturing a colorfilter according to the present invention.

FIGS. 18A, 18B, 18C, 18D, and 18E are process diagrams for explaining aninth embodiment of a method for manufacturing a color filter accordingto the present invention.

FIG. 19 is a diagram showing an example of a color filter according tothe present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention relates to a method for manufacturing a colorfilter, a color filter, and a color liquid crystal display. Hereinafter,each will be explained.

A. Method for Manufacturing a Color Filter

The methods for manufacturing a color filter according to the presentinvention include 9 embodiments. Hereinafter, each will be explained.

1. First Embodiment

A first embodiment of a method for manufacturing a color filteraccording to the present invention is a method comprising:

(1) forming a light shielding part on a transparent base material;(2) forming a wettability changeable layer, which a wettability changesby a function of a photocatalyst, on a surface of the transparent basematerial on a side which the light shielding part is formed;(3) placing a photocatalyst containing layer of a photocatalystcontaining layer side substrate, which is the photocatalyst containinglayer containing a photocatalyst formed on a base member, and thewettability changeable layer with a gap of 200 μm or less, andirradiating an energy from a predetermined direction to form a pixelpart forming part, in a pattern, comprising a lyophilic area where thecontact angle to a liquid is lowered compared with a state before theenergy irradiation to the wettability changeable layer; and(4) coloring the pixel part forming part by an ink jet method so as toform a pixel part.

In this embodiment, as shown in FIGS. 1A, 1B, 1C, 1D, and 1E as anexample, a light shielding part 2 is formed on a transparent basematerial 1 (FIG. 1A), a wettability changeable layer 3 is formed on thesurface, and a color filter substrate 4 is prepared (FIG. 1B). Next, aphotocatalyst containing layer 23, formed on a base member 22 of aphotocatalyst containing layer side substrate 21, is placed with acertain gap to the above mentioned wettability changeable layer 3. Then,with a photomask 24 placed on the base member 22 side of thephotocatalyst containing layer side substrate 21, an energy 10 isirradiated in a pattern (FIG. 1C). Thereby, a pattern which thewettability is changed is formed in a pixel part forming part 5 on thesurface of the above mentioned wettability changeable layer 3 (FIG. 1D).Thereafter, by taking out the photocatalyst containing layer sidesubstrate 21, and coloring the pixel part forming part 5 with a pixelpart forming ink 12 by an ink jet apparatus 11 (FIG. 1D), a pixel part 6is formed (FIG. 1E).

Thereafter, these processes will be explained separately. A color filtersubstrate in this embodiment denotes a substrate on which a color filteris formed, and thus it denotes an intermediate product before completinga color filter.

(Process for Forming a Light Shielding Part)

First, a process for forming a light shielding part will be explained.As the light shielding part in this embodiment, for example, as shown inFIG. 1A, the light shielding part 2 is formed on the transparent basematerial 1 by a conventional method. The transparent base material andthe light shielding part to be used in the light shielding part formingprocess in this embodiment as mentioned above will be explainedhereafter.

As it is shown in FIGS. 1A, 1B, 1C, 1D, and 1E as an example, in thetransparent base material in this embodiment, the light shielding part 2and the wettability changeable layer 3 to be described later areprovided on the transparent base material 1. The transparent basematerial is not particularly limited as long as it is one conventionallyused for a color filter. For example, a transparent rigid materialwithout flexibility such as a quartz glass, a pyrex (registeredtrademark), and a synthetic quartz plate, or a transparent flexiblematerial having flexibility such as a transparent resin film and anoptical resin plate can be used. Among them, since the 7059 glassmanufactured by Corning Incorporated is a material having a smallthermal expansion coefficient, the excellent in size stability and inworkability at a high temperature heating process, and it is a nonalkaline glass not containing an alkaline component in the glass, it isparticularly suitable for a color filter for a color liquid crystaldisplay by an active matrix method. In this embodiment, a transparentone is generally used as the transparent base material, however, areflective base material or abase material colored in white can be usedas well. Moreover, for transparent base material, those with a surfaceprocess for preventing alkaline elution, providing a gas barrierproperty, or for other purposes applied can be used as needed.

In this embodiment, the method for manufacturing the light shieldingpart on the above mentioned transparent base material is notparticularly limited. For example, a method of forming a metal thin filmof a chromium or the like by about 1,000 to 2,000 Å thickness by asputtering method, a vacuum deposition method, or the like, andpatterning the thin film can be presented.

Moreover, the above mentioned light shielding part may be a layercontaining light shielding particles of carbon fine particles, a metaloxide, an inorganic pigment, an organic pigment, or the like in a resinbinder. In this embodiment, the resin light shielding part ispreferable. The thickness of the resin light shielding part can be setin a range of 0.5 to 10 μm. In general, the thickness can be providedthicker than the case of using a metal thin film.

Moreover, as the resin binder to be used, one kind or a mixture of twoor more kinds of resins such as a polyimide resin, an acrylic resin, anepoxy resin, a polyacrylic amide, a polyvinyl alcohol, a gelatin, acasein, and a cellulose, or a photo sensitive resin, an O/W emulsiontype resin composition, such as an emulsion of a reactive silicone, orthe like can be used. As the patterning method for the resin lightshielding part, a commonly used method such as a photolithographymethod, a printing method, or the like can be used.

In this embodiment, the resin light shielding part is preferable sinceit can be formed easily by the wet process.

(Process for Forming Wettability Changeable Layer)

Next, the process for forming the wettability changeable layer will beexplained. In the process of forming wettability changeable layer inthis embodiment, for example, as shown in FIG. 1B, a wettabilitychangeable layer 3 is formed on the surface of the color filtersubstrate 2 formed in the above mentioned light shielding part 2 formingprocess. Hereinafter, the wettability changeable layer will beexplained.

The wettability changeable layer in this embodiment may be any layer aslong as it is a layer which the wettability changes by the function of aphotocatalyst.

In this embodiment, the wettability changeable layer may be one formedby a dry process, that is, the vacuum deposition method or the like.Moreover, it may be one formed by a wet process, that is, a method suchas the spin coating method, the dip coating method, or the like.

Here, as to the wettability change in this embodiment, a wettabilitychangeable layer, having a large contact angle to a liquid before theenergy irradiation so as to be changed to have a small contact angle toa liquid after the energy irradiation, may be used. Moreover, incontrast, a wettability changeable layer may have a small contact angleto a liquid before the energy irradiation so as to be changed to have alarge contact angle to a liquid after the energy irradiation. In thisembodiment, in particular, a layer which the wettability is changed soas to have the contact angle to a liquid on the wettability changeablelayer surface lowered by the function of the photocatalyst accompaniedby the energy irradiation is preferable because a lyophilic area patternhaving a small contact angle to a liquid can be formed easily.

Here, the lyophilic area is an area having a small contact angle to aliquid. Since the pixel part to be described later can be formed easilyin the lyophilic area by the ink jet method, a color filter can bemanufactured efficiently so that it is advantageous in terms of thecost. Moreover, the liquid repellent area is an area having a largecontact angle to a liquid.

In this embodiment, in the case the contact angle of the area to aliquid is smaller than the contact angle to a liquid of the adjacentarea by one degree or more, it is referred to as the lyophilic area, andin contrast, in the case the contact angle of the area to a liquid islarger than the contact angle to a liquid of the adjacent area by onedegree or more, it is referred to as the liquid repellent area.

For the above mentioned wettability changeable layer, in the partwithout the energy irradiation, that is, the liquid repellent area, itis preferable that the contact angle to a liquid having a 40 mN/msurface tension is 100 or more, more preferably the contact angle to aliquid having a 30 mN/m surface tension is 10° or more, and particularlypreferably the contact angle to a liquid having a 20 mN/m surfacetension is 10° or more. Here, since the part without the energyirradiation is the part required to have the liquid repellent propertyin this embodiment, in the case the contact angle to a liquid is smallerthan the above mentioned range, the liquid repellent property isinsufficient so that a highly sophisticated pattern can hardly beformed, and thus it is not preferable.

Moreover, it is preferable that the above mentioned wettabilitychangeable layer is a layer which becomes a lyophilic area by loweringthe contact angle to a liquid by the energy irradiation to have thecontact angle to a liquid having a 40 mN/m surface tension of 90 orless, more preferably the contact angle to a liquid having a 50 mN/msurface tension of 100 or less, and particularly preferably the contactangle to a liquid having a 60 mN/m surface tension of 10° or less. Inthe case the contact angle to a liquid in the part with the energyirradiation, that is, in the lyophilic area is higher than the abovementioned range, spreading of the ink for coloring the pixel part inthis part may be poor so that a problem of the color omission, the colorirregularity, or the like may be generated.

The contact angle to a liquid here is a value obtained from the resultsor a graph of the results of measuring (30 seconds after dropping liquiddroplets form a micro syringe) the contact angle to liquids havingvarious surface tensions using a contact angle measuring device (CA-Ztype manufactured by Kyowa Interface Science, Co., Ltd.). Moreover, atthe time of the measurement, as the liquids having the various surfacetensions, wetting index standard solutions manufactured by JunseiChemical Co., Ltd. were used.

Moreover, in the case the above mentioned wettability changeable layeris used in this embodiment, it is also possible that the wettabilitychangeable layer contains a fluorine, and furthermore, the wettabilitychangeable layer is formed such that when an energy is irradiated to thewettability changeable containing layer, the fluorine content of thewettability changeable layer surface is lowered, compared to the statebefore the energy irradiation, by the function of the above mentionedphotocatalyst.

In the wettability changeable layer having such characteristics, by theenergy irradiation, a pattern comprising a part with a small fluorinecontent can be formed easily. Here, since the fluorine has an extremelylow surface energy, the surface of a substance containing a large amountof a fluorine has a smaller critical surface tension. Therefore, thecritical surface tension of a part with a small fluorine content islarger than the critical surface tension of the surface of a part with alarge fluorine content. That is, it denotes that the part with a smallfluorine content becomes a lyophilic area compared with the part with alarge fluorine content. Therefore, by forming a pattern comprising apart with a small fluorine content compared with the surface of theperiphery, a pattern of a lyophilic area is formed in a liquid repellentarea.

Therefore, in the case such a wettability changeable layer is used,since a lyophilic area pattern can be formed easily in the liquidrepellent area by the energy irradiation, the pixel part can be easilyformed only in the lyophilic area so that a color filter with a goodquality can be provided at a low cost.

As to the fluorine content in the wettability changeable layercontaining a fluorine as mentioned above, the fluorine content in thelyophilic area having a low fluorine content formed by the energyirradiation is 10 or less based on the fluorine content in the areawithout the energy irradiation as 100, it is more preferably 5 or less,and particularly preferably 1 or less.

By setting within the above mentioned range, a large difference of thewettability between the energy irradiated part and the unirradiated partcan be generated. Therefore, by forming a pixel part or a lightshielding part on such wettability changeable layer, the pixel part orthe light shielding part can be formed accurately only on the lyophilicarea, where the fluorine content lowered, so that a color filter can beobtained accurately. The lowering ratio is based on the weight.

As to the measurement of the fluorine content in the wettabilitychangeable layer, various methods commonly executed can be used, and itis not particularly limited as long as it is a method capable ofmeasuring the fluorine amount on the surface quantitatively, forexample, the X-ray photoelectron spectroscopy, the ESCA (it is alsoreferred to as the electron spectroscopy for chemical analysis), thefluorescent X ray analysis method, and the mass analysis method.

As the material used for such a wettability changeable layer, it is notparticularly limited as long as it is a material which the wettabilityof the above mentioned wettability changeable layer, that is, thewettability is changed by the photocatalyst in the photocatalystcontaining layer to be contacted, by the energy irradiation, and it hasa principal chain to be hardly deteriorated or decomposed by thefunction of the photocatalyst. For example, (1) an organo polysiloxanewhich provides high strength by hydrolyzing or polycondensating a chloroor alkoxy silane, or the like by the sol gel reaction or the like, (2)an organo polysiloxane such as an organo polysiloxane obtained bycross-linking a reactive silicone having the excellent water repellentproperty or oil repellent property, or the like can be presented.

In the above mentioned case (1), it is preferably an organo polysiloxanewhich is a hydrolyzed condensate or a co-hydrolyzed condensate of onekind or two or more kinds of silicon compounds represented by thegeneral formula:

Y_(n)SiX_((4-n))

(Here, Y is an alkyl group, a fluoro alkyl group, a vinyl group, anamino group, a phenyl group, an epoxy group or an organic groupcontaining them, X is an alkoxyl group, or a halogen, and n is aninteger from 0 to 3.). Here, the number of atoms of the entire organicgroup represented by Y is preferably in a range of 1 to 20. Moreover,the alkoxy group represented by X is preferably a methoxy group, anethoxy group, a propoxy group, or a butoxy group.

Moreover, an organo polysiloxane containing a fluoro alkyl group can beused particularly preferably. Specifically, a hydrolyzed condensate or aco-hydrolyzed condensate of one kind or two or more kinds of thefollowing fluoro alkyl silanes can be presented. Those generally knownas a fluorine based silane coupling agent can be used.

-   CF₃(CF₂)₃CH₂CH₂Si(OCH₃)₃;-   CF₃(CF₂)₅CH₂CH₂Si(OCH₃)₃;-   CF₃(CF₂)₇CH₂CH₂Si(OCH₃)₃;-   CF₃(CF₂)₉CH₂CH₂Si(OCH₃)₃;-   (CF₃)₂CF(CF₂)₄CH₂CH₂Si(OCH₃)₃;-   (CF₃)₂CF(CF₂)₆CH₂CH₂Si(OCH₃)₃;-   (CF₃)₂CF(CF₂)₈CH₂CH₂Si(OCH₃)₃;-   CF₃(C₆H₄)C₂H₄Si(OCH₃)₃;-   CF₃(CF₂)₃(C₆H₄)C₂H₄Si(OCH₃)₃;-   CF₃(CF₂)₅(C₆H₄)C₂H₄Si(OCH₃)₃;-   CF₃(CF₂)₇(C₆H₄)C₂H₄Si(OCH₃)₃;-   CF₃(CF₂)₃CH₂CH₂SiCH₃(OCH₃)₂;-   CF₃(CF₂)₅CH₂CH₂SiCH₃(OCH₃)₂;-   CF₃(CF₂)₇CH₂CH₂SiCH₃(OCH₃)₂;-   CF₃(CF₂)₉CH₂CH₂SiCH₃(OCH₃)₂;-   (CF₃)₂CF (CF₂)₄CH₂CH₂SiCH₃(OCH₃)₂;-   (CF₃)₂CF (CF₂)₆CH₂CH₂SiCH₃(OCH₃)₂;-   (CF₃)₂CF(CF₂)₈CH₂CH₂SiCH₃(OCH₃)₂;-   CF₃(C₆H₄)C₂H₄SiCH₃(OCH₃)₂;-   CF₃(CF₂)₃(C₆H₄)C₂H₄SiCH₃(OCH₃)₂;-   CF₃(CF₂)₅(C₆H₄)C₂H₄SiCH₃(OCH₃)₂;-   CF₃(CF₂)₇(C₆H₄)C₂H₄SiCH₃(OCH₃)₂;-   CF₃(CF₂)₃CH₂CH₂Si(OCH₂CH₃)₃;-   CF₃(CF₂)₅CH₂CH₂Si(OCH₂CH₃)₃;-   CF₃(CF₂)₇CH₂CH₂Si(OCH₂CH₃)₃;-   CF₃(CF₂)₉CH₂CH₂Si(OCH₂CH₃)₃; and-   CF₃(CF₂)₇SO₂N(C₂H₅)C₂H₄CH₂Si(OCH₃) 3.

By using the polysiloxane containing the above mentioned fluoro alkylgroup as a binder, the liquid repellent property of the energyunirradiated part of the wettability changeable layer can be improveddramatically so that, for example, a function of preventing adhesion ofan ink for coloring the pixel part can be realized.

Moreover, as the above mentioned reactive silicone of the abovementioned (2), compounds having a skeleton represented by the followinggeneral formula can be presented.

In the above general formula, n is an integer of 2 or more, R¹, R² eachare a substituted or non substituted alkyl, alkenyl, aryl or cyano alkylgroup having 1 to 10 carbon atoms, and 40% or less of the entirety basedon the molar ratio is a vinyl, a phenyl, or a halogenated phenyl.Moreover, those having R¹, R² as a methyl group are preferable since thesurface energy becomes smallest, and it is preferable that a methylgroup accounts for 60% or more based on the molar ratio. Moreover, atleast one reactive group such as a hydroxyl group is provided in amolecular chain at the chain end or the side chain.

Moreover, together with the above mentioned organo polysiloxane, astable organo silicone compound not to have the cross-linking reactionsuch as a dimethyl polysiloxane can be mixed.

In this embodiment, various kinds of the materials such as an organopolysiloxane can be used for the wettability changeable layeraccordingly. As mentioned above, it is effective that a fluorine iscontained in the wettability changeable layer in terms of thewettability pattern formation. Therefore, it is preferable to form thewettability changeable layer with a material which is hardlydeteriorated or decomposed by the function of a photocatalyst,specifically an organo polysiloxane material, containing a fluorine.

As a method of making a fluorine to be contained in the organopolysiloxane material, a method of bonding a fluorine compound to aprincipal agent, which generally has a high bonding energy, byrelatively weak bonding energy, a method of mixing a fluorine compoundwhich was bonded by a relatively weak bonding energy, into thewettability changeable layer, or the like can be listed. By introducinga fluorine by such methods, in the case the energy is irradiated, thefluorine bonding portion having a relatively weak bonding energy isfirst decomposed, and thereby the fluorine can be removed from thewettability changeable layer.

As the above mentioned first method, that is, as a method of bonding afluorine compound to a binder, having high bonding energy, by arelatively weak bonding energy, a method of introducing a fluoro alkylgroup to the above mentioned organo polysiloxane as a substituent, orthe like can be presented.

For example, as a method for obtaining an organo polysiloxane, asmentioned above as (1), an organo polysiloxane capable of providing highstrength can be obtained by the hydrolyzing or the polycondensating of achloro, alkoxy silane, or the like by the sol gel reaction or the like.Here, in this method, as mentioned above, an organo polysiloxane isobtained by the hydrolysis condensating or the co-hydrolysiscondensating of one kind or two or more kinds of silicon compoundsrepresented by the general formula:

Y_(n)SiX_((4-n))

(Here, Y is an alkyl group, a fluoro alkyl group, a vinyl group, anamino group, a phenyl group, an epoxy group or an organic groupcontaining them, X is an alkoxyl group, or a halogen, and n is aninteger from 0 to 3.). In the general formula, by the synthesis using asilicon compound having a fluoro alkyl group as the substituent Y, anorgano polysiloxane having a fluoro alkyl group as a substituent can beobtained. In the case such an organo polysiloxane having a fluoro alkylgroup as the substituent is used as the binder, at the time energy isirradiated, since the carbon bonding portion of the fluoro alkyl groupis decomposed by the function of the photocatalyst in the photocatalystcontaining layer to be contacted, the fluorine content of the part, ofthe photocatalyst containing layer where the energy is irradiated, canbe reduced.

As the silicon compound having a fluoro alkyl group used at the time, itis not particularly limited as long as it has a fluoro alkyl group, anda silicon compound having at least one fluoro alkyl group, with thefluoro alkyl group having 4 to 30 carbon atoms, preferably 6 to 20carbon atoms, and particularly preferably 6 to 16 carbon atoms can beused preferably. The specific examples of such a silicon compound are asmentioned above. In particular, the above mentioned silicon compoundhaving a fluoro alkyl group having 6 to 8 carbon atoms, that is, afluoro alkyl silane is preferable.

In this embodiment, it is possible to use such a silicon compound havinga fluoro alkyl group as a mixture with the above mentioned siliconcompound not having a fluoro alkyl group, and use the co-hydrolyzedcondensate of them as the above mentioned organo polysiloxane, or to useone kind or two or more kinds of the silicon compounds having a fluoroalkyl group and use the hydrolyzed condensate or the co-hydrolyzedcondensate thereof as the above mentioned organo polysiloxane.

As for an organo polysiloxane having a fluoro alkyl group accordinglyobtained, among the silicon compound comprising the organo polysiloxane,it is preferable that the above mentioned silicon compound having afluoro alkyl group is contained by 0.01 mole % or more, and preferablyby 0.1 mole % or more.

By containing the fluoro alkyl group to about this degree, the liquidrepellent property on the wettability changeable layer can be improvedso that the wettability difference to the part provided as the lyophilicarea by the energy irradiation can be made larger.

Moreover, in the above mentioned method (2), an organo polysiloxane isobtained by cross-linking of a reactive silicone having the excellentliquid repellent property. Also in this case, a fluorine can becontained in the wettability changeable layer by having either one orboth of R¹, R², in the above mentioned general formula, as a substituentcontaining a fluorine such as a fluoro alkyl group. Moreover, in thecase energy is irradiated, since the fluoro alkyl group having bondingenergy lower than that of the siloxane bond is decomposed, the fluorinecontent in the surface of the wettability changeable layer can belowered by the energy irradiation.

In contrast, in the latter case, that is, as a method for introducing afluorine compound bonded by energy lower than the bonding energy of thebinder, in the case of introducing a low molecular weight fluorinecompound, for example, a method of mixing a fluorine based surfactant orthe like can be presented. Moreover, as a method for introducing a highmolecular weight fluorine compound, a method of mixing a fluorine resinhaving high compatibility with the binder resin, or the like can bepresented.

For the wettability changeable layer in this embodiment, a surfactantcan further be contained. Specifically, hydrocarbon based ones of theNIKKOL BL, BC, BO, BB series manufactured by Nikko Chemicals Co., Ltd.,fluorine based or silicone based nonionic surfactants such as ZONYL FSN,FSO manufactured by Dupont, SURFLONS-141, 145 manufactured by AsahiGlass Company, MAGAFAKKU F-141, 144 manufactured by Dainippon Ink andChemicals, Incorporated, FUTAGENT F-200, F251 manufactured by NeosCorp., UNIDYNE DS-401, 402 manufactured by Daikin Industries, Ltd., andFLUORAD FC-170, 176 manufactured by 3M, can be presented. Moreover,cationic surfactants, anionic surfactants, amphoteric surfactants can beused as well.

Moreover, for the wettability changeable layer, in addition to the abovementioned surfactants, oligomers and polymers, such as a polyvinylalcohol, an unsaturated polyester, an acrylic resin, a polyethylene, adiallyl phthalate, an ethylene propylene diene monomer, an epoxy resin,a phenol resin, a polyurethane, a melamine resin, a polycarbonate, apolyvinyl chloride, a polyamide, a polyimide, a styrene butadienerubber, a chloroprene rubber, a polypropylene, a polybutylene, apolystyrene, a polyvinyl acetate, a polyester, a polybutadiene, apolybenzimidazol, a polyacrylic nitrile, an epichlorohydrine, apolysulfide, a polyisoprene, and the like can be contained.

Such a wettability changeable layer can be formed by dispersing theabove mentioned components in a solvent, as needed with other additives,so as to prepare a coating solution, and coating the coating solutiononto a substrate. As the solvent to be used, alcohol based organicsolvents such as an ethanol, and an isopropanol are preferable. Thecoating can be carried out by a known coating method such as spincoating, spray coating, dip coating, roll coating and bead coating. Inthe case an ultraviolet ray curing type component is contained, thewettability changeable layer can be formed by carrying out a curingprocess by irradiating an ultraviolet ray.

In this embodiment, the thickness of the wettability changeable layer ispreferably from 0.001 μm to 1 μm in terms of the wettability change rateor the like by the photocatalyst, and particularly preferably it is in arange of 0.01 to 0.1 μm.

In this embodiment, by using the wettability changeable layer of theabove mentioned components, the wettability of the energy irradiatedpart can be changed so as to be lyophilic, by using the function of theoxidation, the decomposition, or the like of the organic group or theadditives which is a part of the above mentioned components by thefunction of the photocatalyst in the photocatalyst containing layer tobe contacted so as to generate a large difference of the wettability tothe energy unirradiated part. Therefore, by improving the receptivity(lyophilic property) and the repulsion property (liquid repellentproperty) to an ink or the like for coloring the pixel part, a colorfilter with a good quality and advantageous in terms of the cost can beobtained.

The wettability changeable layer used in this embodiment is notparticularly limited as long as it is a layer which the wettability ischanged by the function of a photocatalyst as mentioned above, but it isparticularly preferably a layer not containing a photocatalyst. In thecase a photocatalyst is not contained in the wettability changeablelayer accordingly, it can be used for a color filter thereafter withoutthe concern of the influence by the photocatalyst by the time passage sothat it can be used without problem generation over a long time.

(Process for Forming a Pixel Part Forming Part Comprising a LyophilicArea in a Pattern)

Next, the process for forming a pattern of the pixel part forming partcomprising a lyophilic area in this embodiment will be explained. Asshown in FIG. 1C as an example, this process is a process of placing aphotocatalyst containing layer 23 of a photocatalyst containing layerside substrate 21 and the wettability changeable layer 3 with a gap of200 μm or less therebetween, and irradiating an energy 10 along thepattern of the pixel part forming part, to provide a pattern of thelyophilic area which the wettability of the pixel part forming part 5,on the surface of the above mentioned wettability changeable layer, ischanged as shown in FIG. 1D. In the above mentioned process, first, thephotocatalyst containing layer substrate is prepared, then, thephotocatalyst containing layer substrate is placed with a gap to theabove mentioned wettability changeable layer, and then the energy isirradiated. Hereafter, these processes will be explained.

a. Preparation of the Photocatalyst Containing Layer Substrate

First, the photocatalyst containing layer side substrate used in thisembodiment will be explained.

The photocatalyst containing layer side substrate comprises a basemember, and a photocatalyst containing layer containing a photocatalystformed on the base member. Such a photocatalyst containing layer sidesubstrate comprises at least the photocatalyst containing layer and thebase member. In general, it is formed of a thin film-like photocatalystcontaining layer formed on the base member by a predetermined method.Moreover, as the photocatalyst containing layer side substrate, thosehaving a light shielding part formed in a pattern can be used as well.Hereinafter, each constitution will be explained.

(i) Photocatalyst Containing Layer

The photocatalyst containing layer used in this embodiment is notparticularly limited as long as it has a configuration in which thephotocatalyst in the photocatalyst containing layer changes thewettability of the subject wettability changeable layer. It may comprisea photocatalyst and a binder, or it may be a film formed with aphotocatalyst alone. Moreover, the wettability of its surface may eitherbe lyophilic or liquid repellent.

The photocatalyst containing layer used in this embodiment may have thephotocatalyst containing layer 23 formed on the entire surface of thebase member 22 of the photocatalyst containing layer side substrate 21,as shown in FIG. 2A for example, or it may have the photocatalystcontaining layer 23 formed in a pattern on the base member 22 of thephotocatalyst containing layer side substrate 21, as shown in FIG. 3 forexample.

By accordingly forming the photocatalyst containing layer in a pattern,as it will be explained in the energy irradiating process describedlater, at the time of irradiating the energy with the photocatalystcontaining layer and the wettability changeable layer placed with apredetermined gap provided therebetween, the pattern irradiation using aphotomask or the like is not needed, so that a pattern which thewettability is changed can be formed on the wettability changeable layerby the irradiation to the entire surface.

The method for patterning the photocatalyst processing layer is notparticularly limited, and for example, it can be carried out by thephotolithography method or the like.

Moreover, since the wettability only in the part on the wettabilitychangeable layer actually facing the photocatalyst containing layer ischanged, as to the energy irradiation direction, the energy may beirradiated from any direction as long as it is irradiated to the partwhere the above mentioned photocatalyst containing layer and thewettability changeable layer face to each other, and furthermore, theenergy to be irradiated is not limited to parallel ones such as aparallel light beam, and thus it is advantageous.

Although the function mechanism of the photocatalyst represented by atitanium dioxide, which is described later, in the photocatalystcontaining layer is not clear, it is considered that a carrier producedby the light beam irradiation influences the chemical structure of anorganic substance by the direct reaction with a compound in thevicinity, or by the active oxygen specie produced in the presence of anoxygen and water. In this embodiment, it is considered that the carrierinfluences the compound in the wettability changeable layer placed inthe vicinity of the photocatalyst containing layer.

As the photocatalyst used in this embodiment, those known as photosemiconductors, such as a titanium dioxide (TiO₂), a zinc oxide (ZnO), atin oxide (SnO₂), a strontium titanate (SrTiO₃), tungsten oxide (WO₃),bismuth oxide (Bi₂O₃), and an iron oxide (Fe₂O₃) can be presented, andone kind or two or more kinds as a mixture can be selected and used fromthem.

In this embodiment, in particular, a titanium dioxide can be usedpreferably since it has high band gap energy, it is chemically stablewithout the toxicity, and it can be obtained easily. There are ananatase type and a rutile type in the titanium dioxides, and either canbe used in this embodiment, and the anatase type titanium dioxide ispreferable. The excitation wavelength of the anatase type titaniumdioxide is 380 nm or less.

As the anatase type titanium dioxide, for example, a hydrochloric acidpeptization type anatase type titania sol (STS-02 (average particle size7 nm) manufactured by Ishihara Sangyo Kaisha, Ltd., ST-K01 manufacturedby Ishihara Sangyo Kaisha, Ltd.), a nitric acid peptization type anatasetype titania sol (TA-15 (average particle size 12 nm) manufactured byNissan Chemical Industries, Ltd.), or the like can be presented.

With a smaller particle size of the photocatalyst, the photocatalystreaction can be generated effectively, and thus it is preferable. Anaverage particle size of 50 nm or less is preferable, and use of aphotocatalyst of 20 nm or less is particularly preferable.

The photocatalyst containing layer in this embodiment may be one formedwith the photocatalyst alone, or one formed as a mixture with a binder,as mentioned above.

In the case of the photocatalyst containing layer formed only with thephotocatalyst, the efficiency in terms of the wettability change on thewettability changeable layer is improved so that it is advantageous interms of the cost, such as the processing time reduction. In contrast,in the case of the photocatalyst containing layer formed with thephotocatalyst and the binder, it is advantageous in terms of theformation easiness of the photocatalyst containing layer.

As the method for forming the photocatalyst containing layer formed onlywith the photocatalyst, for example, a sputtering method, a CVD method,and a method using a vacuum film formation method, such as a vacuumdeposition method, can be presented. By forming the photocatalystcontaining layer by the vacuum film formation method, a photocatalystcontaining layer containing only a photocatalyst can be provided as aneven film, and thereby, the wettability on the wettability changeablelayer can be changed evenly. Moreover, since it is formed only with thephotocatalyst, compared with the case of using the binder, thewettability on the wettability changeable layer can be changedefficiently.

Moreover, as the method for forming the photocatalyst containing layerformed only with the photocatalyst, for example, in the case thephotocatalyst is a titanium dioxide, a method of forming an amorphoustitania on the base member, and changing the phase to a crystallinetitania by baking, or the like can be presented. The amorphous titaniaused here can be obtained by, for example, hydrolyzing or dehydrationcondensating of a inorganic salt of titanium such as a titaniumtetrachloride, and a titanium sulfide, or hydrolyzing, or dehydrationcondensating under the existence of an acid of an organic titaniumcompound such as a tetraethoxy titanium, a tetraisopropoxy titanium, atetra-n-propoxy titanium, a tetrabutoxy titanium, and a tetramethoxytitanium. Next, by baking at 400° C. to 500° C., it can be denatured toan anatase type titania, and by baking at 600° C. to 700° C., it can bedenatured to a rutile type titania.

Moreover, in the case of using a binder, it is preferable that theprincipal skeleton of the binder has a high bonding energy so as not tobe decomposed by the photo excitation of the above mentionedphotocatalyst. For example, an organo polysiloxane or the like can bepresented.

In the case an organo polysiloxane is used as the binder accordingly,the above mentioned photocatalyst containing layer can be formed bydispersing the photocatalyst and the organo polysiloxane as the binderin a solvent as needed with the other additives so as to prepare acoating solution, and coating the coating solution on the base member.As the solvent to be used, alcohol based organic solvents such as anethanol, and an isopropanol are preferable. The coating can be carriedout by a known coating method such as spin coating, spray coating, dipcoating, roll coating and bead coating. In the case an ultraviolet raycuring type component is contained in the binder, the photocatalystcontaining layer can be formed by carrying out a curing process byirradiating an ultraviolet ray.

Moreover, as the binder, an amorphous silica precursor can be used. Theamorphous silica precursor is represented by the general formula SiX₄. Xis preferably a silicon compound such as a halogen, a methoxy group, anethoxy group, an acetyl group, or the like, a silanol as a hydrolysisproduct thereof, or a polysiloxane having a 3,000 or less averagemolecular weight.

Specifically, a tetraethoxy silane, a tetraisopropoxy silane, atetra-n-propoxy silane, a tetrabutoxy silane, a tetramethoxy silane, orthe like can be presented. Moreover, in this case, by homogeneouslydispersing the precursor of an amorphous silica and the photocatalystparticles in a nonaqueous based solvent, forming a silanol on the basemember by the hydrolyzing by the moisture content in the air, andcarrying out the dehydration polycondensation at an ordinarytemperature, the photocatalyst containing layer can be formed. Bycarrying out the dehydration polycondensation of a silanol at 100° C. ormore, the polymerization degree of the silanol is increased so that thefilm surface strength can be improved. Moreover, the bonding agents canbe used alone or as a mixture of two or more kinds.

The photocatalyst content in the photocatalyst containing layer in thecase of using a binder can be set in a range of 5 to 60% by weight,preferably 20 to 40% by weight. Moreover, the thickness of thephotocatalyst containing layer is preferably in a range of 0.05 to 10μm.

Moreover, for the photocatalyst containing layer, in addition to theabove mentioned photocatalyst and binder, a surfactant can be contained.Specifically, hydrocarbon based ones of the NIKKOL BL, BC, BO, BB seriesmanufactured by Nikko Chemicals Co., Ltd., fluorine based or siliconebased nonionic surfactants such as ZONYL FSN, FSO manufactured by DuPont, SURFLON S-141, 145 manufactured by Asahi Glass Company, MAGAFAKKUF-141, 144 manufactured by Dainippon Ink and Chemicals, Incorporated,FUTAGENT F-200, F251 manufactured by Neos Corp., UNIDYNE DS-401, 402manufactured by Daikin Industries, Ltd., and FLUORAD FC-170, 176manufactured by 3M, can be presented. Moreover, cationic surfactants,anionic surfactants, amphoteric surfactants can be used as well.

Moreover, for the photocatalyst containing layer, in addition to theabove mentioned surfactants, oligomers and polymers, such as a polyvinylalcohol, an unsaturated polyester, an acrylic resin, a polyethylene, adiallyl phthalate, an ethylene propylene diene monomer, an epoxy resin,a phenol resin, a polyurethane, a melamine resin, a polycarbonate, apolyvinyl chloride, a polyamide, a polyimide, a styrelene butadienerubber, a chloroprene rubber, a polypropylene, a polybutylene, apolystyrene, a polyvinyl acetate, a polyester, a polybutadiene, apolybenzimidazol, a polyacrylic nitrile, an epichlorohydrine, apolysulfide, a polyisoprene, and the like can be contained.

(ii) Base Member

In this embodiment, as shown in FIG. 2A, the photocatalyst containinglayer side substrate 21 comprises at least the base member 22 and thephotocatalyst containing layer 23 formed on the base member 22. At thetime, the material used for forming the base member is selectedoptionally according to the energy irradiation direction in the energyirradiating process to be described later, whether the color filter tobe obtained requires the transparency, or the like.

In the case of preliminarily forming the photocatalyst containing layerside light shielding part in a predetermined pattern on thephotocatalyst containing layer side substrate as it will be explainedlater, and forming a pattern using the photocatalyst containing layerside light shielding part, or in the case of forming a pattern using aphotomask 24 on the photocatalyst containing layer side substrate sideas shown in FIG. 2B for the pattern formation, it is necessary to placethe photomask 24 on the photocatalyst containing layer side substrate 23side, and irradiate an energy from the photocatalyst containing layerside substrate side. In this case, the base member needs to have thetransparency.

In contrast, it is also possible to irradiate the energy with thephotomask placed on the color filter substrate side. Moreover, in thecase the light shielding part is formed preliminarily on the colorfilter substrate, it is possible to irradiate the energy from the colorfilter substrate side. In this case, the base member transparency is notparticularly needed.

Moreover, the base member used in this embodiment may be one having theflexibility, such as a resin film, or one not having the flexibility,such as a glass substrate. This can be selected optionally according tothe method for irradiating energy in the energy irradiating process tobe described later.

Accordingly, although the material of the base member used for thephotocatalyst containing layer side substrate in this embodiment is notparticularly limited, since the photocatalyst containing layer sidesubstrate is used repeatedly in this embodiment, a material havingpredetermined strength, and the surface having a good adhesiveness tothe photocatalyst containing layer can be used preferably.

Specifically, a glass, a ceramic, a metal, a plastic, or the like can bepresented.

For improving the adhesiveness of the base member surface and thephotocatalyst containing layer, an anchor layer may be formed on thebase member. As the anchor layer, for example, a silane based ortitanium based coupling agent or the like can be presented.

(iii) Photocatalyst Containing Layer Side Light Shielding Part

As the photocatalyst containing layer side substrate used in thisembodiment, one having the photocatalyst containing layer side lightshielding part formed in a pattern may be used. By using thephotocatalyst containing layer side substrate having the photocatalystcontaining layer side light shielding part accordingly, use of aphotomask or execution of the drawing irradiation with a laser lightbeam is not needed at the time of the energy irradiation. Therefore,since positioning of the photocatalyst containing layer side substrateand the photomask is not needed, the process can be a simple process.Moreover, since expensive equipment needed for the drawing irradiationis unnecessary, it is advantageous in terms of the cost.

The photocatalyst containing layer side substrate having thephotocatalyst containing layer side light shielding part may be providedin the following two embodiments according to the position of formingthe photocatalyst containing layer side light shielding part.

One of them is, as shown in FIG. 4, an embodiment of forming thephotocatalyst containing layer side light shielding part 25 on the basemember 22 of the photocatalyst containing layer side substrate 21, andforming the photocatalyst containing layer 23 on the photocatalystcontaining layer side light shielding part 25. The other one is, asshown in FIG. 5, an embodiment of forming the photocatalyst containinglayer 23 on the base member 22 of the photocatalyst containing layerside substrate 21, and forming the photocatalyst containing layer sidelight shielding part 25 thereon.

In either embodiment, compared with the case of using the photomask,since the photocatalyst containing layer side light shielding part isplaced in the vicinity of the part where the above mentionedphotocatalyst containing layer and the wettability changeable layer areplaced with a gap, the influence by the energy scattering in the basemember or the like can be reduced, and thus the energy patternirradiation can be carried out extremely accurately.

Furthermore, in the embodiment of forming the photocatalyst containinglayer side light shielding part on the above mentioned photocatalystcontaining layer, by matching the film thickness of the photocatalystcontaining layer side light shielding part with the width of the gap atthe time of placing the photocatalyst containing layer and thewettability changeable layer with a certain gap, it is advantageous inthat the above mentioned photocatalyst containing layer side lightshielding part can be used also as a spacer for providing the abovementioned gap constantly.

That is, at the time of placing the above mentioned photocatalystcontaining layer and the wettability changeable layer in a contactedstate with a predetermined gap, by placing the above mentionedphotocatalyst containing layer side light shielding part and thewettability changeable layer in a state contacted closely, the abovementioned predetermined gap can be provided accurately. Furthermore, byirradiating the energy from the photocatalyst containing layer sidesubstrate in this state, a pattern can be formed accurately on thewettability changeable layer.

The method for forming the photocatalyst containing layer side lightshielding part is not particularly limited, and thus it can be selectedand used optionally according to the wettability of the formed surfaceof the photocatalyst containing layer side light shielding part, theneeded shielding property to the energy, or the like.

Here, since the methods for forming and the material for thephotocatalyst containing layer side light shielding part in thisembodiment is same as the above mentioned light shielding part,explanation is omitted here. The thickness of the photocatalystcontaining layer side light shielding part can be set in a range of 0.5to 10 μm. As the method for patterning the resin photocatalystcontaining layer side light shielding part, a commonly used method suchas a photolithography method, a printing method, and the like can beused.

Although the two places of forming the photocatalyst containing layerside light shielding part, of between the base member and thephotocatalyst containing layer, and on the photocatalyst containinglayer surface have been explained in the above mentioned explanation, inaddition thereto, an embodiment of forming the photocatalyst containinglayer side light shielding part on the surface of the base member on theside which the photocatalyst containing layer is not formed, can beadopted as well. In this embodiment, for example, the case of adhering aphotomask onto the surface to the detachable degree, or the like isconceivable, and it can be used preferably in the case of changing thecolor filters in a small lot.

(iv) Primer Layer

In this embodiment, in the case of forming the photocatalyst containinglayer side light shielding part in a pattern on the base member asmentioned above, and forming the photocatalyst containing layer thereonto provide the photocatalyst containing layer side substrate, it ispreferable to form a primer layer in between the above mentionedphotocatalyst containing layer side light shielding part and thephotocatalyst containing layer.

Although the effect and the function of the primer layer is not alwaysclear, it is considered that by forming the primer layer in between thephotocatalyst containing layer side light shielding part and thephotocatalyst containing layer, the primer layer provides the functionof preventing diffusion of the impurities from the opening part existingin the photocatalyst containing layer side light shielding part, or inbetween the photocatalyst containing layer side light shielding parts tobe the factor of inhibiting the wettability change of the wettabilitychangeable layer by the function of the photocatalyst, in particular,the residue generated at the time of patterning the photocatalystcontaining layer side light shielding part, a metal, a metal ion, or thelike. Therefore, by forming the primer layer, the wettability changeprocess can proceed with a high sensitivity, and as a result, a patternwith a high resolution can be obtained.

In this embodiment, since the primer layer is for preventing theinfluence on the photocatalyst effect by the impurities existing notonly on the photocatalyst containing layer side light shielding part butalso in the opening part formed in between the photocatalyst containinglayer side light shielding parts, it is preferable that the primer layeris formed on the entire surface of the photocatalyst containing layerside light shielding part including the opening part.

FIG. 6 shows an example of the photocatalyst containing layer sidesubstrate with the primer layer formed. The primer layer 26 is formed onthe surface of the base member 22 with the photocatalyst containinglayer side light shielding part 25 of the photocatalyst containing layerside substrate 21 formed, on the side which photocatalyst containinglayer side light shielding part 25 is formed, and the photocatalystcontaining layer 23 is formed on the surface of the primer layer 26.

The primer layer in this embodiment is not particularly limited as longas it has a structure in which the primer layer is formed so that thephotocatalyst containing layer side light shielding part of thephotocatalyst containing layer side substrate and the photocatalystcontaining layer do not contact to each other.

The material for constituting the primer layer is not particularlylimited, but an inorganic material which is hardly decomposed by thefunction of the photocatalyst is preferable. Specifically, an amorphoussilica can be presented. In the case of using the amorphous silica, theprecursor of the amorphous silica is represented by the general formulaSiX₄. X is preferably a silicon compound such as a halogen, a methoxygroup, an ethoxy group, an acetyl group, or the like, a silanol as ahydrolysis product thereof, or a polysiloxane having a 3,000 or lessaverage molecular weight.

Moreover, the film thickness of the primer layer is preferably in arange of 0.001 μm to 1 μm, and particularly preferably it is in a rangeof 0.001 μm to 0.1 μm.

b. Energy Irradiating Process

In this embodiment, next, after placing the photocatalyst containinglayer and the wettability changeable layer with a gap of 200 μm or less,a process of irradiating an energy from a predetermined direction, iscarried out. In this process, the photocatalyst containing layer and thewettability changeable layer may be adhered.

In this embodiment, in consideration of the extremely good patternaccuracy, the high photocatalyst sensitivity, and thus the goodwettability change efficiency, it is particularly preferable that theabove mentioned gap is provided in a range of 0.2 μm to 10 μm, morepreferably in a range of 1 μm to 5 μm. The gap range is particularlyeffective for the color filter substrate of a small area which iscapable of controlling the gap with the high accuracy.

In contrast, in the case of processing a color filter substrate of alarge area, for example 300 ml×300 mm or more, it is extremely difficultto form the above mentioned minute gap in between the photocatalystcontaining layer side substrate and the color filter substrate withoutbeing contacted. Therefore, in the case the color filter substrate is ofa relatively large area, it is preferable to provide the above mentionedgap in a range of 10 to 100 μm, in particular, in a range of 50 to 75μm. By setting the gap in the range, the problem of the pattern accuracydecline such as blurring of the pattern, or the problem of thewettability change efficiency deterioration by the deterioration of thephotocatalyst sensitivity, or the like cannot be generated, andfurthermore, the effect of preventing generation of the wettabilitychange irregularity on the wettability changeable layer can be provided.

At the time of irradiating the energy to the color filter substrate ofthe relatively large area, it is preferable to set the gap in thepositioning device for the photocatalyst containing layer side substrateand the color filter substrate in the energy irradiating device in arange of 10 μm to 200 μm, in particular, in a range of 25 μm to 75 μm.By providing the setting value in the range, the photocatalystcontaining layer side substrate and the color filter substrate can beplaced without being contacted, without causing drastic decline of thepattern accuracy or drastic deterioration of the photocatalystsensitivity.

As mentioned above, by placing the photocatalyst containing layer andthe wettability changeable layer surface separated by a predeterminedinterval, the active oxygen species generated by the oxygen, water, andthe photocatalyst function can easily be desorbed. That is, in the casethe interval between the photocatalyst containing layer and thewettability changeable layer is made narrower than the above mentionedrange, the above mentioned active oxygen species can hardly be desorbedso that the wettability change rate may be made lower as a result, andthus it is not preferable. Moreover, in the case they are placed with aninterval larger than the above mentioned range, the generated activeoxygen species can hardly reach the wettability changeable layer so thatthe wettability change rate may be made lower also in this case, andthus it is not preferable.

In this embodiment, the placement state with the gap needs to bemaintained at least during the energy irradiation.

As the method for placing the photocatalyst containing layer and thewettability changeable layer with such an evenly formed extremely narrowgap, for example, a method of using a spacer can be presented. Then, byusing the spacer, an even gap can be formed, and furthermore, since thephotocatalyst function is not provided on the part of the wettabilitychangeable layer surface where being contacted with the spacer, byproviding the spacer in the same pattern as the above mentioned pattern,a predetermined pattern can be formed on the wettability changeablelayer.

In this embodiment, although the spacer can be formed as an member, butfor simplifying the process, it is preferable to form the same on thephotocatalyst containing layer surface of the photocatalyst containinglayer side substrate as it is explained in the column of the abovementioned photocatalyst containing layer side substrate. Although it hasbeen explained as the photocatalyst containing layer side lightshielding part in the explanation for the above mentioned photocatalystcontaining layer side substrate preparing process, since the spacer isonly needed to provide the function of protecting the surface so thatthe photocatalyst function dose not influence the wettability changeablelayer surface in this embodiment, it may be formed of a material notparticularly having the function of shielding the energy to beirradiated.

The energy irradiation (exposure) in this embodiment is the conceptincluding any irradiation of the energy line capable of changing thewettability of the wettability changeable layer surface by thephotocatalyst containing layer, and thus it is not limited to thevisible light beam irradiation.

The light wavelength used for the energy irradiation is generally set ina range of 400 nm or less, preferably in a range of 380 nm or lessbecause the preferable photocatalyst used for the photocatalystcontaining layer is a titanium dioxide as mentioned above, and a lighthaving the above mentioned wavelength is preferable as the energy foractivating the photocatalyst function by the titanium dioxide.

As a light source to be used for the energy irradiation, a mercury lamp,a metal halide lamp, a xenon lamp, an excimer lamp, and various otherlight sources can be presented.

In addition to the method of executing the pattern irradiation via aphotomask using the above mentioned light source, a method of drawingirradiation in a pattern using a laser such as an excimer, a YAG, or thelike can be used as well.

Here, the energy irradiation amount at the time of the energyirradiation is defined to be the irradiation amount necessary forchanging the wettability of the wettability changeable layer surface bythe function of the photocatalyst in the photocatalyst containing layer.

Moreover, at the time, by irradiating the energy while heating thephotocatalyst containing layer, the sensitivity can be raised so thatthe wettability can be changed efficiently, and thus it is preferable inthis regard. Specifically, it is preferable to heat in a range of 30° C.to 80° C.

The energy irradiation direction in this embodiment may either be fromthe photocatalyst containing layer side substrate side, or from thecolor filter substrate side with the above mentioned light shieldingpart provided as the mask. Here, in the case the photocatalystcontaining layer side light shielding part is formed on thephotocatalyst containing layer side substrate, the energy irradiationneeds to be executed form the photocatalyst containing layer sidesubstrate side, and furthermore, in this case, the photocatalystcontaining layer side substrate needs to be transparent to the energy tobe irradiated. In this case, in the case the photocatalyst containinglayer side light shielding part is formed on the photocatalystcontaining layer, and the photocatalyst containing layer sidephotocatalyst containing layer side light shielding part is used so asto have the above mentioned function of the spacer, the energyirradiation direction may either be from the photocatalyst containinglayer side substrate side or from the color filter substrate side.

Moreover, in this embodiment, since the color filter substrate has theabove mentioned light shielding part formed, the entire surface energyirradiation may be executed form the color filter substrate side.Thereby, the energy irradiation can be carried out only to the pixelpart forming part without providing the energy irradiation only to thewettability changeable layer in the part formed on the upper surface ofthe light shielding part. Therefore, the energy pattern irradiation canbe carried out without using a photomask or the like.

Furthermore, as to the energy irradiation direction in the case thephotocatalyst containing layer is formed in a pattern, the energy may beirradiation from any direction as long as it is irradiated to the partwhere the photocatalyst containing layer and the wettability changeablelayer is contacted. Similarly, in the case of using the above mentionedspacer, as long as the energy is irradiated to the contacted part, itmay be irradiated form any direction. Here, in the case a photomask isused, it is necessary that the energy is irradiated form the side whichthe photomask is placed.

When the above mentioned energy irradiation is finished, thephotocatalyst containing layer side substrate is separated form thecontact position with the wettability changeable layer. Thereby, asshown in FIG. 1D, the pixel part forming part 5 with the wettabilitychanged is formed in a pattern on the wettability changeable layer 3.

Here, in this embodiment, it is preferable that the width of the pixelpart is formed wider than the width of the opening part formed by thelight shielding part. Thereby, after being completed as a liquid crystaldisplay, when a backlight is irradiated, there is no possibility oftransmitting the backlight through the part where the pixel part is notformed, so that a trouble of the color omission or the like is notgenerated.

As shown in FIGS. 1A, 1B, 1C, 1D, and 1E as an example, the abovementioned pixel part can be formed by narrowing the width of thephotocatalyst containing layer side light shielding part of thephotomask 24 of the photocatalyst containing substrate 21 for formingthe pixel part forming part 5 comprising the lyophilic area than thelight shielding part 2 of the color filter substrate 4.

(Pixel Part Forming Process)

Next, the process for forming the pixel part in this embodiment will beexplained. According to the above mentioned process, for example asshown in FIG. 1D, the ink 12 is discharged to the pixel part formingpart 5 provided as the lyophilic area by the wettability change, usingthe ink jet apparatus 11 to color in red, green and blue, respectivelyso as to form the pixel part 6.

In this case, since the pixel part forming part 5 is provided as thelyophilic area having a small contact angle to a liquid by the energyirradiation as mentioned above, the ink 12 discharged from the ink jetapparatus 11 is spread evenly in the pixel part forming part 5.Moreover, since the area of the photocatalyst containing layer withoutexecution of the energy irradiation is provided as the liquid repellentarea, the ink is repelled and removed in this area.

The pixel part is generally formed in the three colors of red (R), green(G) and blue (B). The coloring pattern and the coloring area in thepixel part can be set optionally. The inks for forming the pixel part inthe ink jet method can be classified on the whole to the water basedtype and the oil based type. In this embodiment, either type can beused, however, in terms of the surface tension, the water based inks arepreferable.

In the water based inks used in this embodiment, as a solvent, wateralone, or a solvent mixture of water and a water soluble organic solventcan be used. In contrast, in the oil based inks, those having a highboiling point as the base can be used preferably for preventing chokingof the head or the like. As the coloring agents used for these ink jetmethod inks, known pigments and dyes can be used widely. Moreover, it isalso possible to contain soluble or insoluble resins in the solvent forimproving the dispersing property and the fixing property. Additionally,the surfactants such as a nonionic surfactant, a cationic surfactant,and an amphoteric surfactant; the antiseptics; the corrosion preventingagents; the pH adjusting agents; the antifoaming agents; the ultravioletray absorbing agents; the viscosity adjusting agents; the surfacetension adjusting agents, or the like may be added as needed.

Moreover, since an ordinary ink for the ink jet method has a lowsuitable viscosity, it cannot contain a binder resin by a large amount.However, by granulating the coloring agent particles in the ink so as tobe contained by the resin, the fixing ability can be provided to thecoloring agent itself. Such an ink can be used in this embodiment.Furthermore, the so-called hot melt ink or the UV curing type ink can beused as well.

In this embodiment, in particular, it is preferable to use the UV curingtype ink. By using the UV curing type ink, after forming the pixel partby coloring by the ink jet method, the ink can be cured quickly by theUV irradiation so that the next process can be carried out immediately.Therefore, the color filter can be manufactured efficiently. Moreover,as mentioned above, since the ink in the pixel part forming part isspread evenly, by accordingly solidifying the ink, the pixel part can beformed without color omission or color irregularity. Then, as needed,the protecting layer may be provided thereon.

The UV curing type ink contains a prepolymer, a monomer, an opticalinitiator and a coloring agent as the main components. As theprepolymer, any of the prepolymers such as a polyester acrylate, apolyurethane acrylate, an epoxy acrylate, a polyether acrylate, an oligoacrylate, an alkyd acrylate, a polyol acrylate, and a silicon acrylatecan be used without limitation.

As the monomer, vinyl monomers such as a styrene, and a vinyl acetate;monofunctional acrylic monomers such as an n-hexyl acrylate, and aphenoxy ethyl acrylate; and polyfunctional acrylic monomers such as adiethylene glycol diacrylate, a 1,6-hexane diol diacrylate, an esterneopentyl glycol diacrylate hydroxylpiperate, a trimethylol propanetriacrylate, and a dipentaerythritol hexaacrylate can be used. Theabove-mentioned prepolymers and monomers can be used alone or as amixture or two or more kinds.

As the photo polymerization initiator, one capable of obtaining thedesired curing wettability and recording wettability can be usedselectively from an isobutyl benzoin ether, an isopropyl benzoin ether,a benzoin ethyl ether, a benzoin methyl ether, a1-phenyl-1,2-propadion-2-oxime, a 2,2-dimethoxy-2-phenyl acetophenone, abenzyl, a hydroxyl cyclohexyl phenyl ketone, a diethoxy acetophenone, a2-hydroxy-2-methyl-1-phenyl propane-1-on, a benzophenone, a chlorothioxanthone, a 2-chloro thioxanthone, an isopropyl thioxanthone, a2-methyl thioxanthone, a chlorine substituted benzophenone, a halogensubstituted alkyl-allyl ketone, or the like. Additionally, as needed,the photo initiating auxiliary agents such as an aliphatic amine and anaromatic amine; the photo sensitizing agents such as a thioxanthone maybe added.

Moreover, as the ink jet apparatus to be used in this embodiment,although it is not particularly limited, the ink jet apparatus using thevarious kinds of methods such as a method of continuously discharging acharged ink and controlling the same by the magnetic field, a method ofintermittently discharging an ink using a piezoelectric element, and amethod of heating an ink and intermittently discharging the sameutilizing the bubbles, can be used.

Here, in this embodiment, although the pixel part may be formed by theone time energy irradiation and the ink adhesion to the energyirradiated part as mentioned above, in the above mentioned method forforming pixel part, the distance between the pixel part forming parts,which is the lyophilic area with the energy irradiation, is short at thetime of adhering the ink. Therefore, a problem of the ink mixture or thelike may be generated at the time of forming the pixel part. As a methodfor avoiding the problem, a method of executing the energy irradiationand the pixel part formation, divided into at least two times as shownbelow can be presented.

FIGS. 7A, 7B, 7C, and 7D show examples of executing the energyirradiation and formation of the pixel part, divided into two times.Similarly to the example shown in the above FIGS. 1A, 1B, 1C, 1D, and1E, the light shielding part 2 is formed on the transparent basematerial 1, and the wettability changeable layer 3 is formed on thetransparent base material 1 so as to cover the light shielding part 2 toform the color filter forming substrate 4. With the photocatalystcontaining layer 23 formed on the base member 22 of the photocatalystcontaining layer 21 placed so as to face the wettability changeablelayer 3, the energy 10 is irradiated to form the pixel parts in everyother pixel part forming parts, using the photomask 24 (FIG. 7A). Byadhering the pixel part forming ink 12 onto the pixel part forming parts5 of the lyophilic area formed thereby, using the ink jet apparatus 11(FIG. 7B), the pixel parts 6 are formed in the every other parts in thepixel part forming parts (FIG. 7C). For the pixel parts formed here, itis preferable that the pixel parts themselves are liquid repellent toprevent the coloring of the ink by the ink jet apparatus on the pixelparts at the second time. Moreover, the surface thereof may be processedwith an ink repellent processing agent such as a silicone compound, or afluorine containing compound.

Then, by irradiating the energy 10 again, using the photocatalystcontaining substrate 21 from the wettability changeable layer 3 side onwhich the pixel parts 6 is formed in the every other parts, the pixelparts forming parts between the pixel parts 6 can be provided as thepixel part forming parts 5 by the energy irradiation, and by adheringthe pixel part forming ink 12 thereon, using the ink jet apparatus 11,the pixel parts 4 are formed so as to obtain the color filter (FIG. 7D).

According to the method, since the distance between each pixel part canbe reduced or removed, the coloring layer (a pixel part assembly) havingthe excellent flatness can be formed. Moreover, at the time of the firstpixel part formation, since the interval between the formed pixel partsis large, the ink cannot be mixed beyond the parts. Therefore, a highquality color filter without the ink color mixture or the like can beobtained.

Although the pixel parts 6 formed in the first formation is in the everyother parts in the above mentioned method, the present invention is notlimited thereto, and as long as the initially formed pixel parts are notnext to each other, it may be changed depending on the shape of thepixel parts of the color filter, such as the zigzag shape. Moreover,although the pixel parts are formed in two times of the operation in theabove mentioned explanation, the pixel parts may be formed by three ormore times of the operation, as needed.

(Liquid Repellent Convex Part)

In this embodiment, after the process of forming the wettabilitychangeable layer, the process for forming the liquid repellent convexpart exposing part by irradiating the energy to the photocatalystcontaining layer on the light shielding part, and forming the liquidrepellent convex part in the liquid repellent convex part exposing partmay be provided.

An example of the process for forming the liquid repellent convex partwill be explained with reference to FIGS. 8A, 8B, 8C, 8D, and 8E.Similarly to the above mentioned first embodiment shown in FIGS. 1A, 1B,1C, 1D, and 1E, to the color filter forming substrate with the lightshielding part 2 formed on the transparent base material 1, and thewettability changeable layer 3 formed so as to cover the same, an energy10 is irradiated in a liquid repellent convex part pattern, using thephotomask 24, with the photocatalyst containing layer 23 formed on thebase member 22 of the photocatalyst containing layer side substrate 21placed with a certain gap (FIG. 5A). Thereby, the wettability changeablelayer 3 on the light shielding part forming part 2 is provided as thelyophilic area so as to form the pattern with the wettability changed onthe surface of the liquid repellent convex part forming part 7.

To the liquid repellent convex part forming part 7, the liquid repellentconvex part ink 8 such as a UV curing type resin monomer is adhered bythe ink jet apparatus 11 (FIG. 8B). The method for coating the liquidrepellent convex part ink is not limited to the method by the ink jetapparatus, and other methods such as dip coating can be used as well.

Then, by curing the liquid repellent convex part ink 8 by the UVirradiation or the like, the liquid repellent convex part 9 is formed onthe surface of the wettability changeable layer 3 on the light shieldingpart 2 (FIG. 8C). It is preferable that the width of the liquidrepellent convex part 9 is formed narrower than the width of the lightshielding part 2 as shown in the figure. By forming accordingly, theproblem of the color omission or the like is not generated as mentionedabove.

By irradiating the energy 10 to the entire surface of the member,accordingly formed with the liquid repellent convex part 9 formed on thewettability changeable layer 3, from the photocatalyst containingsubstrate 21 side with the photocatalyst containing layer 23 of thephotocatalyst containing layer side substrate 21 and the wettabilitychangeable layer 3 placed with a certain gap, the part other than theportion with the liquid repellent convex part 9 formed is irradiatedwith the energy so as to be the pixel part forming part. Thereafter,similarly to the above mentioned method, by carrying out the energyirradiation using the photocatalyst containing layer side substrate 21,adhering the pixel part forming ink 12 to the pixel part forming part 5which is the wettability changeable layer provided as the lyophilic areaby using the ink jet apparatus 11, and curing, the pixel part 6 isformed so that the color filter provided with the liquid repellentconvex part 9 can be manufactured (FIGS. 8C, 8D, and 8E).

According to the method, since the liquid repellent convex part formingpart 7 is formed by irradiating the energy 10 to the photocatalystcontaining layer 3 on the light shielding part 2, the liquid repellentconvex part forming part 7 can be formed by an optional width.Therefore, by coating the liquid repellent convex part ink 8 here, theliquid repellent convex part 9 of an optional width can be formed.Therefore, by adjusting the width of the liquid repellent part mask, theliquid repellent convex part 9 having a narrower width than that of theabove mentioned light shielding part 2 can be formed. By forming theliquid repellent convex part 9 having a narrower width than that of thelight shielding part 2, since the width of the pixel part 6 to be formedin between the liquid repellent convex parts 9 can be made wider thanthe width of the opening part of the light shielding part 2, a colorfilter without a trouble of the color omission or the like can beobtained as mentioned above.

Although the liquid repellent convex part is formed by the wettabilitychange of the photocatalyst containing layer in this embodiment, thepresent invention is not limited thereto, and for example the liquidrepellent convex part may be provided by the photolithography method.

2. Second Embodiment

The second embodiment of the present invention is a method formanufacturing a color filter comprising:

(1) forming a wettability changeable layer, which a wettability changesby a function of a photocatalyst, on a transparent base material, on apixel part forming part which is a part on the transparent base materialwhere pixel part is formed;(2) forming a light shielding part on the boundary part of the pixelpart forming part provided with the wettability changeable layer;(3) placing a photocatalyst containing layer of a photocatalystcontaining layer side substrate, which is the photocatalyst containinglayer containing a photocatalyst formed on a base member, and thewettability changeable layer with a gap of 200 μm or less, andirradiating an energy from a predetermined direction to obtain the pixelpart forming part as a lyophilic area where the contact angle to aliquid is lowered compared with a state before the energy irradiation;and(4) coloring the pixel part forming part, provided as a lyophilic area,by an ink jet method so as to form a pixel part.

In this embodiment, as shown in FIGS. 9A, 9B, 9C, 9D, and 9E forexample, the wettability changeable layer 3 is formed, on thetransparent base material 1, in the pixel part forming part where thepixel part is formed (FIG. 9A). The light shielding part 2 is formed onthe light shielding part forming part which is the boundary part of thepixel part forming part with the above mentioned wettability changeablelayer 3 formed (FIG. 9B). Next, with the photocatalyst containing layer23 formed on the base member 22 of the photocatalyst containing layerside substrate 21 placed with a certain gap to the above mentionedwettability changeable layer 3, the energy 10 is irradiated (FIG. 9C) toform a pattern with the wettability changed on the pixel part formingpart 5 on the surface of the above mentioned wettability changeablelayer 3 (FIG. 9D). Thereafter, by detaching the photocatalyst containinglayer side substrate 21, and coloring the pixel part forming part 5,which the wettability is changed, with the pixel part forming ink 12 bythe ink jet apparatus 11 (FIG. 9D), the pixel part 6 is formed (FIG.1E). Hereinafter, each will be explained, respectively.

(Wettability Changeable Layer Forming Process)

First, the wettability changeable layer 3 is formed, on the transparentbase material 1, in the portion where the pixel part is formed (FIG.9A). That is, in the method, the wettability changeable layer 3 is firstformed in a pattern on the transparent base material. As a method forforming the wettability changeable layer in a pattern, for example, amethod for forming by the photolithography method using a photosensitive sol gel solution, a method by printing, or the like can bepresented.

Since the transparent base material and the wettability changeable layerused here are same as those in the first embodiment, explanation isomitted here.

Here, as to the transparent base material, since the light shieldingpart is formed on the transparent base material as it will be explainedlater, among the above mentioned transparent base materials of the firstembodiment, the wettability on the transparent base material ispreferably lyophilic in this embodiment. Specifically, it is preferablethat the contact angle to a liquid having a 40 mN/m surface tension isless than 10 degrees, more preferably, the contact angle to a liquidhaving a 40 mN/m surface tension is 5 degrees or less, and particularlypreferably it is 1 degree or less. Moreover, the surface of thetransparent base material may have the surface process so as to belyophilic. As an example of the surface process to have the materialsurface lyophilic, the lyophilic surface process by the plasma processutilizing an argon, water, or the like can be presented. As thelyophilic layer formed on the transparent base material, for example, asilica film of a tetraethoxy silane by the sol gel method or the likecan be presented.

(Light Shielding Part Forming Process)

The light shielding part 2 is formed by coating the light shielding partpaint or the like onto the part without the wettability changeable layer3 (light shielding part forming part), formed in the above mentionedwettability changeable layer forming process, using for example the inkjet apparatus or the like (FIG. 9B). As mentioned above, the wettabilityof the surface of the wettability changeable layer 3 is provided asliquid repellent compared with the surface of the transparent basematerial 1. Thereby, at the time of forming the light shielding part 2by the ink jet method or the like, the light shielding part paint isadhered only on the light shielding part forming part on the transparentbase material 1, without being adhered onto the wettability changeablelayer having the liquid repellent property so as to form the lightshielding part.

Here, the method for forming the light shielding part in this embodimentis not limited to the above mentioned ink jet method, and thephotolithography method or the like may be used.

Moreover, since the light shielding part used in this embodiment is sameas that of the first embodiment, explanation is omitted here.

(Process for Forming a Pixel Part Forming Part Comprising a LyophilicArea in a Pattern)

Next, after formation of the light shielding part 2 by the abovementioned process, similarly to the first embodiment, the photocatalystcontaining layer side substrate 21 is prepared. With the photocatalystcontaining layer 23 of the photocatalyst containing layer side substrate21 placed with a gap to the above mentioned wettability changeable layer3, the energy 10 irradiation is carried out (FIG. 9C). Since thephotocatalyst containing layer side substrate and the energy irradiationprocess used in this embodiment are same as those of the firstembodiment, explanation is omitted here.

Here, in this embodiment, by the above mentioned energy irradiation, notonly the pixel part forming part can be provided as lyophilic, but alsothe impurities on the color filter generated in the above mentionedlight shielding part forming process can be removed at the same time. Inthe case the above mentioned light shielding part is formed for exampleby the photolithography method, a cleaning process is generally neededafter the light shielding part formation, and it is carried out by themethod such as the irradiation of the UV to the entire surface with alow pressure mercury lamp, an excimer lamp, or the like. However, inthis embodiment, since the organic substances on the color filtersubstrate can also be decomposed by irradiating the energy by using theabove mentioned photocatalyst containing layer side substrate, thecleaning process is not necessary, and thus it is preferable also interms of the manufacturing efficiency and the cost.

(Pixel Part Forming Process)

Next, by the process of forming the pixel part forming part comprisingthe above mentioned lyophilic area in a pattern, the pixel part 6 isformed by the ink jet method in the pixel part forming process providedas the lyophilic area (FIGS. 9D and E). Since the pixel part formingprocess in this embodiment is same as the first embodiment in terms ofthe ink jet apparatus, the various kinds of inks, or the like,explanation is omitted here.

3. Third Embodiment

The third embodiment of the present invention is a method formanufacturing a color filter comprising:

(1) forming a wettability changeable layer, which a wettability changesby a function of a photocatalyst, on a transparent base material, on alight shielding part forming part which is a part on the transparentbase material where light shielding part is formed;(2) coloring a part on the transparent base material, where thewettability changeable layer is not firmed, by an ink jet method so asto form a pixel part;(3) placing a photocatalyst containing layer of a photocatalystcontaining layer side substrate, which is the photocatalyst containinglayer containing a photocatalyst formed on a base member, and thewettability changeable layer with a gap of 200 μm or less, andirradiating an energy from a predetermined direction to obtain the lightshielding part forming part as a lyophilic area where the contact angleto a liquid is lowered compared with a state before the energyirradiation; and(4) forming a light shielding part in the light shielding part formingpart provided as the lyophilic area.

In this embodiment, as shown in FIGS. 10A, 10B, 10C, and 10D forexample, the wettability changeable layer 3 is formed in the lightshielding part forming part, where the light shielding part is formed,on the transparent base material 1 (FIG. 10A) The pixel part 6 is formedon the pixel part forming part which is the boundary part of the lightshielding part forming part with the above mentioned wettabilitychangeable layer 3 formed, by coloring with the pixel part forming ink12 by the ink jet apparatus 11 (FIG. 10B). Next, with the photocatalystcontaining layer 23 formed on the base member 22 of the photocatalystcontaining layer side substrate 21 placed with a certain gap to theabove mentioned wettability changeable layer 3, the energy 10 isirradiated to form a pattern with the wettability changed on the lightshielding part forming part 13 on the surface of the above mentionedwettability changeable layer 3 (FIG. 10C). Thereafter, by detaching thephotocatalyst containing layer side substrate 21, the light shieldingpart 2 is formed on the light shielding part forming part 13 with thewettability changed (FIG. 10D). Hereinafter, each will be explained,respectively.

(Wettability Changeable Layer Forming Process)

In this embodiment, first, the wettability changeable layer 3 is formedin a pattern, on the transparent base material 1, in the light shieldingpart forming part where the light shielding part is formed (FIG. 10A).Since the method for forming the wettability changeable layer 3 in apattern is same as the method used in the above mentioned secondembodiment, and furthermore, since the transparent base material and thewettability changeable layer are same as those in the first and secondembodiments, explanation is omitted here.

(Pixel Part Forming Process)

Next, the pixel part forming process will be explained. The pixel part 6is formed by adhering the ink, by the ink jet apparatus, to the portionwhere the wettability changeable layer 3 is not formed in the abovementioned wettability changeable layer forming process, that is, to thepixel part forming part where the pixel part is formed (FIG. 10B). Atthe time of forming the pixel part 6, the method for forming ofexecuting the energy irradiation and the pixel part formation divided intwo or more times as explained in the above mentioned first embodimentmay be used because the inks may be mixed due to the narrow liquidrepellent area between the pixel parts 6 at the time of forming thepixel parts 6.

Here, since the ink jet apparatus, the pixel part forming ink, or thelike are same as those in the first embodiment, explanation is omittedhere.

(Process for Forming a Light Shielding Part Forming Part Comprising aLyophilic Area in a Pattern)

After formation of the pixel part 6 by the above mentioned process,similarly to the first embodiment, the photocatalyst containing layerside substrate 21 is prepared. With the photocatalyst containing layer23 of the photocatalyst containing layer side substrate 21 placed with agap provided to the above mentioned wettability changeable layer 3, theenergy 10 irradiation is carried out to provide the light shielding partforming part as the lyophilic area (FIG. 10C). Since the photocatalystcontaining layer side substrate and the energy irradiation process usedin this embodiment are same as those of the first embodiment,explanation is omitted here.

(Light Shielding Part Forming Process)

Next, the light shielding part is formed on the light shielding partforming part provided as the lyophilic area by the above mentionedprocess by the ink jet method or the like. Since the light shieldingpart forming process of this embodiment is same as that of the secondembodiment, explanation is omitted here.

4. Fourth Embodiment

The fourth embodiment of the present invention is a method formanufacturing a color filter comprising:

(1) placing a wettability changeable layer, which a wettability changesby a function of a photocatalyst, and a photocatalyst containing layerof a photocatalyst containing layer side substrate, which is thephotocatalyst containing layer containing a photocatalyst formed on abase member, with a gap of 200 μm or less, and irradiating an energyfrom a predetermined direction to form the light shielding part formingpart, in a pattern, comprising a lyophilic area where the contact angleto a liquid is lowered compared with a state before the energyirradiation;(2) forming a light shielding part in the light shielding part formingpart provided as the lyophilic area;(3) placing a wettability changeable layer with the light shielding partformed thereon and a photocatalyst containing layer with a gap of 200 μmor less, and irradiating an energy from a predetermined direction toform a pixel part forming part, in a pattern, comprising a lyophilicarea where the contact angle to a liquid is lowered compared with astate before the energy irradiation; and(4) coloring the pixel part forming part provided as the lyophilic areaby the ink jet method, so as to form a pixel part.

In this embodiment, as shown in FIGS. 11A, 11B, 11C, 11D, and 11E forexample, the light shielding part forming part 13 with the wettabilitychanged is formed by placing the photocatalyst containing layer 23formed on the base member 22 of the photocatalyst containing layer sidesubstrate 21 with a certain gap to the wettability changeable layer 3,and irradiating the energy 10 in a pattern using the photomask 24 (FIG.11A). Next, the light shielding part 2 is formed on the above mentionedlight shielding part forming part 13 with the wettability changed (FIG.11B).

Next, the pixel part forming part 5 provided as the lyophilic area isformed by placing the photocatalyst containing layer 23 formed on thebase member 22 of the photocatalyst containing layer side substrate 21with a certain gap to the wettability changeable layer 3, andirradiating the energy 10 (FIG. 11C). By coloring the pixel part formingpart 5, with the wettability changed, with the pixel part forming ink 12by the ink jet apparatus 11 (FIG. 11D), the pixel part 6 is formed (FIG.11E). Hereinafter, each will be explained, respectively.

(Process for Forming a Light Shielding Part Forming Part Comprising aLyophilic Area in a Pattern)

Also in this embodiment, as in the first embodiment, the photocatalystcontaining layer side substrate 21 is prepared. With the photocatalystcontaining layer 23 of the photocatalyst containing layer side substrate21 placed with a gap to the wettability changeable layer 3, the energy10 irradiation is carried out only on the light shielding part formingpart (FIG. 11A). By the energy irradiation, the light shielding partforming part is formed in a pattern as the lyophilic area. Since thepixel part forming part remains without the energy irradiation, it isprovided as the liquid repellent area. In this embodiment, the patternformation is carried out, utilizing the liquid repellent propertydifference between the irradiated pattern and the unirradiated pattern.The photocatalyst containing layer side substrate used in thisembodiment is not particularly limited as long as only the lightshielding part can be irradiated with the energy in a pattern as it isdescribed in the first embodiment, a photomask may be used, or it mayhave the photocatalyst containing layer formed in a pattern, or thephotocatalyst containing layer and the light shielding part.

Since the photocatalyst containing layer side substrate and the energyirradiation process used in this embodiment are same as those of thefirst embodiment, explanation is omitted here.

Here, the wettability changeable layer of this embodiment may have ormay not have the self supporting property, or one without the selfsupporting property. The self supporting property in this embodimentdenotes the state capable of existing with a shape without othersupporting material.

As the material for the wettability changeable layer used in thisembodiment, specifically, similarly to the first embodiment, thematerials having the contact angle to a liquid having a surface tensionequivalent to the surface tension of the ink, for the pixel part or forthe light shielding part to be coated thereafter, is changed by at least1° or more, preferably 5°, and particularly preferably 10° or more bythe energy irradiation with the photocatalyst containing layer contactedto the surface can be presented.

Moreover, the wettability changeable layer needs to be made of amaterial capable of transmitting the irradiated energy.

As such materials, for example, a polyethylene, a polycarbonate, apolypropylene, a polystyrene, a polyester, a polyvinyl fluoride, anacetal resin, a nylon, an ABS, a PTFE, a methacrylic resin, a phenolresin, a polyvinylidene fluoride, a polyoxy methylene, a polyvinylalcohol, a polyvinyl chloride, a polyethylene terephthalate, a silicone,or the like can be presented.

In the case of the wettability changeable layer without the abovementioned self supporting property, it is preferable to provide theprocess for forming the wettability changeable layer on the transparentbase material described in the first embodiment. In this embodiment, thewettability changeable layer without the self supporting property ispreferable. The wettability changeable layer made of the abovementionedmaterial which the wettability changes drastically is generally hardly amaterial having the self supporting property so that the strength or thelike is increased by forming on the transparent base material so that itcan be used for the various color filters.

(Light Shielding Part Forming Process)

Next, the light shielding part is formed on the light shielding partforming part provided as the lyophilic area by the above mentionedprocess by the ink jet method or the like. In this case, as mentionedabove, since the pixel part forming part which is not provided aslyophilic is liquid repellent, the light shielding part can be formedeasily by the ink jet method or the like. Since the light shielding partforming process of this embodiment is same as that of the secondembodiment, explanation is omitted here.

(Process for Forming a Pixel Part Forming Part Comprising a LyophilicArea in a Pattern)

Next, similarly to the process for forming the light shielding partforming part in a pattern, the wettability changeable layer 3 of thecolor filter substrate, with the light shielding part formed by theabove mentioned process, is placed with a gap to the photocatalystcontaining layer 23 of the photocatalyst containing layer side substrate21, and the energy 10 irradiation is carried out to the pixel partforming part (FIG. 11C). By the energy irradiation, the pixel partforming part is formed in a pattern as the lyophilic area. The energyirradiation in this case may be carried out either in a pattern or onthe entire surface. Furthermore, in this embodiment, the impurities canbe removed by the energy irradiation in the above mentioned lightshielding part forming process as in the second embodiment. Since theprocess of forming the pixel part forming part in a pattern in thisembodiment is same as that in the first embodiment, explanation isomitted here.

(Pixel Part Forming Process)

Furthermore, the pixel part is formed by the ink jet method in the pixelpart forming part provided as the lyophilic area formed in the abovementioned process for forming the pixel part forming part in a pattern.Since the pixel part forming process in this embodiment is same as thatin the first embodiment, explanation is omitted here.

5. Fifth Embodiment

The fifth embodiment of the present invention is a method formanufacturing a color filter comprising:

(1) placing a wettability changeable layer, which a wettability changesby a function of a photocatalyst, and a photocatalyst containing layerof a photocatalyst containing layer side substrate, which is thephotocatalyst containing layer containing a photocatalyst formed on abase member, with a gap of 200 μm or less, and irradiating an energyfrom a predetermined direction to form a pixel part forming part, in apattern, comprising a lyophilic area where the contact angle to a liquidis lowered compared with a state before the energy irradiation;(2) forming a pixel part by coloring the pixel part forming partprovided as the lyophilic area by an ink jet method;(3) placing a wettability changeable layer with the pixel part formedthereon and a photocatalyst containing layer with a gap of 200 μm orless, and irradiating an energy from a predetermined direction to form alight shielding part forming part, in a patter, comprising a lyophilicarea where the contact angle to a liquid is lowered compared with astate before the energy irradiation; and(4) forming a light shielding part in the light shielding part formingpart provided as the lyophilic area.

In this embodiment, as shown in FIGS. 12A, 12B, 12C, and 12D forexample, the pixel part forming part 5 comprising the lyophilic area isformed by placing the photocatalyst containing layer 23 formed on thebase member 22 of the photocatalyst containing layer side substrate 21with a certain gap to the wettability changeable layer 3, andirradiating the energy 10 using the photomask 24 in a pattern (FIG.12A). Next, the pixel part forming part 5 comprising the lyophilic areais colored with the pixel part forming ink 12 by the ink jet apparatus11 (FIG. 12B) so as to produce the pixel part 6. Next, by placing thephotocatalyst containing layer 23 formed on the base member 22 of thephotocatalyst containing layer side substrate 21 with a certain gap tothe wettability changeable layer 3, and irradiating the energy 10 (FIG.12C), the light shielding part forming part 13 comprising the lyophilicarea is formed. The light shielding part 2 is formed on the lightshielding part forming part 13 comprising the lyophilic area (FIG. 12D).Hereinafter, each will be explained, respectively.

(Process for Forming a Pixel Part Forming Part Comprising a LyophilicArea in a Pattern)

First, also in this embodiment, similarly to the fourth embodiment, thephotocatalyst containing layer side substrate 21 is prepared. With thephotocatalyst containing layer 23 of the photocatalyst containing layerside substrate 21 and the wettability changeable layer 3 placed with agap therebetween, the energy 10 is irradiated to only the pixel partforming part (FIG. 12A). By the energy irradiation, the pixel partforming part is formed in a pattern as the lyophilic area. Since thelight shielding part forming part remains without the energyirradiation, it is provided as liquid repellent. Also in thisembodiment, the pattern formation is carried out, utilizing the liquidrepellent property difference between the irradiated pattern and theunirradiated pattern as in the fourth embodiment.

The transparent wettability changeable layer used in this embodiment mayhave or may not have the self supporting property, as the fourthembodiment. In the case of the wettability changeable layer without theself supporting property, it is preferable to provide the process offorming the wettability changeable layer on the transparent basematerial as described in the first embodiment.

Since the photocatalyst containing layer side substrate and the energyirradiation process used in this embodiment are same as those of thefirst and fourth embodiments, explanation is omitted here.

(Pixel Part Forming Process)

Next, the pixel part is formed by the ink jet method in the pixel partforming part provided as the lyophilic area which was formed in theprocess for forming the above mentioned pixel part forming part in apattern (FIG. 12B). Since the pixel part forming process of thisembodiment is same as that of the first embodiment, explanation isomitted here.

Moreover, in this embodiment, the formation method of executing theenergy irradiation and the pixel part formation divided into two or moretimes of operations explained in the first embodiment may be usedbecause the inks may be mixed due to the narrow liquid repellent areabetween the pixel parts 6 at the time of forming the pixel parts 6.

(Process for Forming a Light Shielding Part Forming Part Comprising aLyophilic Area in a Pattern)

Next, the wettability changeable layer 3 of the color filter substratewith the pixel part formed in the above mentioned process is placed witha gap to the photocatalyst containing layer 23 of the photocatalystcontaining layer side substrate 21 as in the process for forming thepixel part forming part in a pattern, the energy 10 irradiation iscarried out to the light shielding part forming part (FIG. 12C). By theenergy irradiation, the light shielding part forming part is formed in apattern as the lyophilic area. The energy irradiation in this case maybe carried out in a pattern or to the entire surface. Since the energyirradiation process for forming the pattern is same as that of the firstembodiment, explanation is omitted here.

(Light Shielding Part Forming Process)

Next, the light shielding part is formed by the ink jet method on thelight shielding part forming part provided as the lyophilic area in theabove mentioned process. Since the light shielding part forming processof this embodiment is same as that of the second embodiment, explanationis omitted here.

6. Sixth Embodiment

The sixth embodiment of the present invention is a method formanufacturing a color filter comprising:

(1) forming a light shielding part on a wettability changeable layer,which a wettability changes by a function of a photocatalyst;(2) placing a photocatalyst containing layer of a photocatalystcontaining layer side substrate, which is the photocatalyst containinglayer containing a photocatalyst formed on a base member, and thewettability changeable layer with a gap of 200 μm or less, andirradiating an energy from a predetermined direction to form a pixelpart forming part, in a patter, comprising a lyophilic area where thecontact angle to a liquid is lowered compared with a state before theenergy irradiation; and(3) coloring the pixel part forming part provided as the lyophilic areaby the ink jet method so as to form a pixel part.

In this embodiment, as shown in FIGS. 13A, 13B, 13C, and 13D forexample, the light shielding part 2 is formed on the wettabilitychangeable layer 3 (FIG. 13A). Next, with the photocatalyst containinglayer 23 formed on the base member 22 of the photocatalyst containinglayer side substrate 21 placed with a certain gap to the wettabilitychangeable layer 3, the energy 10 is irradiated in a pattern (FIG. 13B).Thereby, the pattern with the wettability changed is formed on the pixelpart forming part 5 on the surface of the above mentioned wettabilitychangeable layer 3. Thereafter, by detaching the photocatalystcontaining layer side substrate 21, and coloring the pixel part formingpart 5 with a pixel part forming ink 12 by the ink jet apparatus 11(FIG. 13C), the pixel part 6 is formed (FIG. 13D). Hereinafter, eachwill be explained, respectively.

(Light Shielding Part Forming Process)

In this embodiment, first the light shielding part is formed on thewettability changeable layer (FIG. 13A). As to the light shielding part,among the light shielding parts described in the first embodiment, oneformed by the photolithography method is preferable, and explanation isomitted here.

Moreover, the wettability changeable layer used in this embodiment mayhave or may not have the self supporting property. Since the samewettability changeable layer explained in the fourth embodiment can beused as the wettability changeable layer used in this embodiment,explanation is omitted here.

(Process for Forming a Pixel Part Forming Part Comprising a LyophilicArea in a Pattern)

Next, the process for forming the pixel part forming part comprising thelyophilic area in a pattern will be explained.

After formation of the light shielding part 2 in the above mentionedprocess, similarly to the first embodiment, the photocatalyst containinglayer side substrate 21 is prepared. With the photocatalyst containinglayer 23 of the photocatalyst containing layer side substrate 21 placedwith a gap to the above mentioned wettability changeable layer 3, theenergy 10 irradiation is carried out (FIG. 13B). Since the photocatalystcontaining layer side substrate and the energy irradiation process usedin this embodiment are same as those of the first embodiment,explanation is omitted here. Furthermore, in this embodiment, theimpurities can be removed by the energy irradiation in the abovementioned light shielding part forming process as in the secondembodiment.

Moreover, in this embodiment, as in the first embodiment, the energy maybe irradiated form the color filter substrate side.

(Pixel Part Forming Process)

The pixel part is formed by the ink jet method in the pixel part formingpart comprising the lyophilic area formed in the above mentioned processfor forming the pixel part forming part in a pattern (FIGS. 13C and13D). Since the pixel part forming process of this embodiment is same asin the first embodiment, explanation is omitted here.

7. Seventh Embodiment

The seventh embodiment of the present invention is a method formanufacturing a color filter comprising:

(1) forming a light shielding part on a transparent base material;(2) forming a decomposition removal layer, on the surface of thetransparent base material on the side with the light shielding partformed, having a higher contact angle to a liquid than the transparentbase material surface, and is decomposed and removed by the function ofa photocatalyst;(3) placing a photocatalyst containing layer of a photocatalystcontaining layer side substrate, which is the photocatalyst containinglayer containing a photocatalyst formed on a base member, and thedecomposition removal layer with a gap of 200 μm or less, andirradiating an energy from a predetermined direction to form a pixelpart forming part, in a pattern, comprising the transparent basematerial bared by the decomposition removal of the decomposition removallayer; and(4) coloring the pixel part forming part by the ink jet method so as toform a pixel part.

In this embodiment, as shown in FIGS. 14A, 14B, 14C, 14D, and 14E forexample, the light shielding part 2 is formed on the transparent basematerial 1 (FIG. 14A), and the decomposition removal layer 3 is formedon the surface for preparing the color filter substrate 4 (FIG. 14B).Next, with the photocatalyst containing layer 23 formed on the basemember 22 of the photocatalyst containing layer side substrate 21 andthe decomposition removal layer 3 placed with a certain gaptherebetween, the energy 10 is irradiated form the photocatalystcontaining layer side substrate 21 side using the photomask 24 (FIG.14C). Thereby, the decomposition removal layer 3 of the pixel partforming part with the energy irradiated is decomposed and removed. Here,since the above mentioned decomposition removal layer 3 has a highercontact angle to a liquid than that of the surface of the abovementioned transparent base material 1, the area where the transparentbase material 1 is bared by decomposition and removal of thedecomposition removal layer 3 can be provided as the lyophilic area, andthe area where the above mentioned decomposition removal layer 3 isremaining can be provided as the liquid repellent area. Thereby, thepixel part forming part 5 which the decomposition removal layer 3 isdecomposed and removed in the above mentioned process is provided as thelyophilic area, and by adhering the pixel part forming part ink 12 tothe pixel part forming part 5 using the ink jet apparatus 11, the pixelpart 6 is formed (FIGS. 14D and 14E).

Hereafter, each process will be explained separately. The color filtersubstrate in this embodiment denotes a substrate, of a color filter usedfor a liquid crystal display, in a state of being in a manufacturingprocess.

(Light Shielding Part Forming Process)

First, the light shielding part forming process will be explained. Inthe light shielding part of this embodiment, as shown in FIG. 14A forexample, the light shielding part 2 is formed on the transparent basematerial 1 by the conventional method. The transparent base material andthe light shielding part used in the light shielding part formingprocess of this embodiment will be explained hereinafter.

In this embodiment, as shown in FIGS. 14A, 14B, 14C, 14D, and 14E forexample, the light shielding part 2 to be described later, and thedecomposition removal layer 3 are provided on the transparent basematerial 1. As the transparent base material, it is not particularlylimited as long as it is one conventionally used for a color filter. Forexample, a transparent rigid material without flexibility, such as aquartz glass, a pyrex (registered trademark), and a synthetic quartzplate, and a transparent flexible material having flexibility, such as atransparent resin film and an optical resin plate can be used. Amongthese, since the 7059 glass manufactured by Corning Incorporated is amaterial having a small thermal expansion coefficient having theexcellent size stability and the workability in a high temperatureheating process, and furthermore, it is a non alkaline glass notcontaining an alkaline component in the glass, it is particularlysuitable for a color filter for a color liquid crystal display by theactive matrix method. In this embodiment, as the transparent basematerial, transparent one is generally used, but a reflective basemember and a base member colored in white can be used as well. Moreover,the transparent base material with the surface process applied, forpreventing the alkaline elution, providing the gas barrier property, andfor other purpose, can be used as needed.

In this embodiment, it is preferable that the transparent base materialis lyophilic. Specifically, it is preferable that the contact angle to aliquid having a 40 mN/m surface tension is less than 10 degrees, morepreferably, the contact angle to a liquid having a 40 mN/m surfacetension is 5 degrees or less, and particularly preferably it is 1 degreeor less. Moreover, a surface process may be carried out to thetransparent base material so as to have the surface lyophilic. As anexample of the surface process to have the material surface lyophilic,the lyophilic surface process by the plasma process utilizing an argon,water, or the like can be presented. As the lyophilic layer formed onthe transparent base material, for example, a silica film of atetraethoxy silane by the sol gel method, or the like can be presented.In this embodiment, the part where the transparent base material isbared is generally provided as the lyophilic area.

Here, in this embodiment, in the case the contact angle of the area to aliquid is smaller than the contact angle to a liquid of the adjacentarea by one degree or more, it is referred to as the lyophilic area, andin contrast, in the case the contact angle of the area to a liquid islarger than the contact angle to a liquid of the adjacent area by onedegree or more, it is referred to as the liquid repellent area.

The contact angle to a liquid here is obtained from the results or agraph of the results of measuring (30 seconds after dropping liquiddroplets form a micro syringe) the contact angle to liquids havingvarious surface tensions using a contact angle measuring device (CA-Ztype manufactured by Kyowa Interface Science, Co., Ltd.). Moreover, atthe time of the measurement, as the liquids having the various surfacetensions, wetting index standard solution manufactured by JunseiChemical Co., Ltd. were used.

Next, the light shielding part in this embodiment will be explained.

In this embodiment, the above mentioned method for forming the lightshielding part on the transparent base material is not particularlylimited, and a method by forming a metal thin film of a chromium or thelike by about 1,000 to 2,000 Å thickness by the sputtering method, thevacuum deposition method, or the like and patterning this thin film canbe presented.

Moreover, as the above mentioned light shielding part, it may be a layercontaining light shielding particles such as carbon fine particles, ametal oxide, an inorganic pigment and an organic pigment in the resinbinder. In this embodiment, the resin light shielding part ispreferable. The thickness of the resin light shielding part can be setin a range of 0.5 to 10 μm. In general, the thickness can be providedthicker than the case of using a metal thin film.

As the resin binder to be used, one kind or a mixture of two or morekinds of resins such as a polyimide resin, an acrylic resin, an epoxyresin, a polyacrylamide, a polyvinyl alcohol, a gelatin, a casein, acellulose, or the like, a photosensitive resin, and furthermore, an O/Wemulsion type resin composition such as an emulsion of a reactivesilicone or the like can be used. As the method for patterning the resinlight shielding part, a commonly known method such as photolithographyand a printing method can be used. In this embodiment, the resin lightshielding part is preferable because it can be formed easily by the wetprocess.

(Decomposition Removal Layer Forming Process)

Next, the process for forming the decomposition removal layer will beexplained. In the decomposition removal layer forming process of thisembodiment, as shown in FIG. 14B for example, the decomposition removallayer 3 is formed on the color filter substrate 4 formed in the abovementioned light shielding part 2 forming process. Hereafter, thedecomposition removal layer will be explained.

The decomposition removal layer in this embodiment may be any layer aslong as it has a higher contact angle to a liquid compared with theabove mentioned transparent base material, and it can be decomposed andremoved by the function of the photocatalyst.

Accordingly, since the decomposition removal layer, of the part with theenergy irradiation, is decomposed and removed by the function of thephotocatalyst, a pattern of the part having the decomposition removallayer and the part not having the same, that is, a pattern with theruggedness can be formed without carrying out the developing process orthe cleaning process.

The decomposition removal layer is oxidized and removed by the functionof the photocatalyst by the energy irradiation so as to be vaporized orthe like, it can be removed without a special post process such as thedeveloping and cleaning process or the like, however, depending on theproperties of the material of the decomposition removal layer, thecleaning process or the like may be carried out.

Moreover, in the decomposition removal layer used in this embodiment,not only because it forms the ruggedness, but also because of the highercontact angle to a liquid of the decomposition removal layer comparedwith the above mentioned transparent base material surface, thedecomposition removal layer is decomposed and removed, so that the areawhere the transparent base material is bared can be provided as thelyophilic area, and the area where the above mentioned decompositionremoval layer is remaining can be provided as the liquid repellent area.Moreover, by adhering the ink to the lyophilic area by the ink jetmethod, various patterns can be formed.

Here, as to the contact angle to a liquid of the decomposition removallayer of this embodiment, it is preferable that the contact angle to aliquid having a 40 mN/m surface tension is 10° or more, preferably thecontact angle to a liquid having a 30 mN/m surface tension is 10° ormore, and in particular, the contact angle to a liquid having a 20 mN/msurface tension is 10° or more. In the case the contact angle to aliquid is smaller than the above mentioned range, it is difficult forthe decomposition removal layer to be decomposed and removed, and toprovide the area where the above mentioned transparent base material isbared as the lyophilic area, and the area where the decompositionremoval layer is remaining as the liquid repellent area so thatformation of a highly sophisticated pattern is difficult. Here, thecontact angle to a liquid is a value measured by the above mentionedmethod. In this embodiment, the part where the decomposition removallayer is accordingly remaining is generally provided as the liquidrepellent area.

As the film usable in the decomposition removal layer, specifically, afilm of a fluorine based or hydrocarbon based liquid repellent resin orthe like can be presented. The fluorine based or hydrocarbon basedresins are not particularly limited as long as they have the liquidrepellent property, and they can be formed by dissolving the resins in asolvent and for example by an ordinary film forming method such as aspin coating method.

Moreover, in the present invention, by use of a functional thin film,that is, a self-assembled monolayer, a Langmuir Blodgett film, and alayer-by-layer self-assembled film, a film without a defect can beformed, and thus it is further preferable to use such film formingmethods.

Here, the self-assembled monolayer, the Langmuir Blodgett film, and thelayer-by-layer self-assembled film used in this embodiment will beexplained specifically.

(i) Self-Assembled Monolayer

Although the present inventors do not know existence of the officialdefinition of the self-assembled monolayer, as the explanation for thosecommonly recognized as the self-assembled monolayers, for example, thecomprehensive bibliography by Abraham Ulman “Formation and Structure ofSelf-Assembled Monolayers”, Chemical Review, 96, 1533-1554 (1996) isexcellent. With reference to the comprehensive bibliography, theself-assembled monolayer can be considered as a monomolecular layergenerated as a consequence of adsorption and coupling (self assembly) ofappropriate molecules on the surface of an appropriate substrate. As thematerial having the self-assembled monolayer forming ability, forexample, surfactant molecules such as a fatty acid, organic siliconmolecules of alkyl trichloro silanes, alkyl alkoxides, or the like,organic sulfur molecules of alkane thiols, or the like, organicphosphoric acid molecules of alkyl phosphates, or the like can bepresented. As the general common property of the molecular structure,they have a relatively long alkyl chain, with the existence of afunctional group to be interacted with the substrate surface on one sideof the molecular end. The alkyl chain part is the source of theintermolecular force at the time of packing the molecules with eachother two dimensionally. The examples shown here have the simpleststructure, and self-assembled monolayers comprising various molecules,such as one having a functional group such as an amino group and acarboxyl group on the other end of the molecule, one whose alkylenechain part is an oxyethylene chain, a fluorocarbon chain, a compositetype chain thereof, or the like, have been reported. Moreover, there isa composite type self-assembled monolayer comprising a plurality ofmolecule species. Moreover, recently, a particle-like polymer having aplurality of functional groups (one functional group in some cases)represented by the dendrimer, and a straight chain-like (with a branchedstructure in some cases) polymer formed on a one layer substrate surface(the latter is referred to as a polymer brush) are also considered to bethe self-assembled monolayers in some cases. In this embodiment, theseare included to the self-assembled monolayers.

(ii) Langmuir Blodgett Film

After formation on the substrate, the Langmuir-Blodgett Film used inthis embodiment is not much different from the above mentionedself-assembled monolayer in terms of the form. The characteristics ofthe Langmuir Blodgett film lie in the forming method and the high twodimensional molecule packing property (high orientation, high order)derived therefrom. That is, in general, the Langmuir Blodgett filmforming molecule is first developed on the gas liquid interface, and thedeveloped film is condensed by the trough so as to be changed into ahighly packed condensed film. Actually, it is transferred onto anappropriate substrate and used. According to the method schematicallyshown here, from a monolayer film to a multiple layer film of optionalmolecule layers can be formed. Moreover, not only a low molecule, butalso a polymer, a colloid particle, or the like can be provided as thefilm material. As to the recent examples using the various materials,they are described in detail in the comprehensive bibliography by TokujiMiyashita, et al. “Perspective to Nano Technology of the Soft Based NanoDevice Creation” polymer 50 vol., September 644-647 (2001).

(iii) Layer-by-Layer Self-Assembled Film

The layer-by layer self-assembled film in general is a film formed bylaminating a material having at least two functional groups with apositive or negative charge consecutively on a substrate by adsorptionand coupling. Since a material having a large number of functionalgroups is advantageous in terms of increase of the film strength and thedurability, recently an ionic polymer (polymer electrolyte) is oftenused as the material. Moreover, particles having the surface charge suchas a protein, a metal, and an oxide, that is, the “colloid particles”are also used frequently as the film forming substance. Furthermore,recently, a film actively utilizing the interaction weaker than the ioncoupling, such as the hydrogen bonding, the coordinate bonding, and thehydrophobic interaction has been reported. As to the relatively recentexamples of the layer-by-layer self-assembled films, they are describedin detail in the comprehensive bibliography by Paula T. Hammond “RecentExplorations in Electrostatic Multilayer Thin Film assembly” CurrentOpinion in Colloid & Interface Science, 4, 430-442 (2000) although it isslightly eccentric to the material system with the electrostaticinteraction provided as the driving force. According to the explanationof the simplest process of the layer-by-layer self-assembled film, it isa film formed by repeating the cycle of adsorption of a material havinga positive (negative) charge-cleaning-adsorption of a material having anegative (positive) charge-cleaning by predetermined times. Unlike theLangmuir Blodgett film, the operation ofdevelopment-condensation-transfer is not needed at all. Moreover, as itis apparent from the manufacturing method difference, the layer-by-layerself-assembled film in general does not have the two dimensional highorientation, high order like the Langmuir Blodgett film. However, thelayer-by-layer self-assembled film and the manufacturing method thereofhave many advantages, which have not been provided in the conventionalfilm forming methods, such as easy formation of a dense film without adefect, and even film formation on a minutely rugged surface, a tubeinner surface, a spherical surface, or the like.

Moreover, as to the film thickness of the decomposition removal layer,it is not particularly limited as long as it is a film thickness to thedegree to be decomposed and removed by the energy irradiated in theenergy irradiating process to be described later. As the specific filmthickness, although it depends drastically on to the kind of the energyto be irradiated, the material of the decomposition removal layer, orthe like, in general it is preferably in a range of 0.001 μm to 1 μm, inparticular in a range of 0.01 μm to 0.1 μm.

(Process for Forming a Pixel Part Forming Part in a Pattern)

Next, the process for forming the pixel part forming part in a patternin this embodiment will be explained. In the process for forming thepixel part forming part in a pattern in this embodiment, as shown inFIG. 14C for example, with the photocatalyst containing layer 23 of thephotocatalyst containing layer side substrate 21 and the decompositionremoval layer 3 placed with a gap of 200 μm or less, the energy 10 isirradiated in a pattern using the photomask 24 for the pixel partforming part pattern. Thereby, a process for forming the pixel partforming part 5 provided as the lyophilic area by the decomposition andremoval of the decomposition removal layer 3 can be provided. In theprocess, the photocatalyst containing layer substrate is first prepared,and the energy irradiation is carried out with the photocatalystcontaining layer substrate placed with a gap to the above mentioneddecomposition removal layer. Since the photocatalyst containing layerside substrate, the energy irradiating method, the irradiationdirection, the energy to be irradiated, or the like used in thisembodiment are same as those in the first embodiment, explanation isomitted here.

(Pixel Part Forming Process)

Next, the process for forming the pixel part in this embodiment will beexplained. According to the above mentioned process, as shown in FIG.14D for example, the pixel part forming ink 12 is discharged to thepixel part forming part 5 with the transparent base material 1 bared andprovided as the lyophilic area using the ink jet apparatus 11 so as tocolor in red, green and blue to form the pixel part 6.

In this case, since the pixel part forming part 5 is provided as thelyophilic area as mentioned above, the pixel part forming ink 12discharged from the ink jet apparatus 11 is spread evenly in the pixelpart forming part 5. Moreover, since the area without the energyirradiation, the area with the decomposition removal layer remaining, isprovided as the liquid repellent area, the ink is repelled and removedin this area.

The pixel part in general is formed with the three colors of red (R),green (G), and blue (B). The coloring pattern and the coloring area inthe pixel part can be set optionally. As the inks to be used for the inkjet method for forming the pixel part, they are classified on the wholeto the water based type and the oil based type. In this embodiment,either type can be used, however, in terms of the surface tension, thewater based inks are preferable.

FIGS. 15A, 15B, 15C and 15D show examples of executing the energyirradiation and the pixel part formation, divided in two times ofoperations. Similarly to the above mentioned example shown in FIGS. 14A,14B, 14C, 14D, and 14E, the light shielding part 2 is formed on thetransparent base material 1, and the decomposition removal layer 3 isformed so as to cover the light shielding part 2. With the decompositionremoval layer 3 and the photocatalyst containing layer 23 of thephotocatalyst containing layer side substrate 21 placed with a certaingap therebetween, the energy 10 is irradiated using the photomask 24 andthe photocatalyst containing substrate so as to form the pixel parts inevery other pixel part forming parts (FIG. 15A). To the every otherpixel part forming part 5 provided as the lyophilic area with thedecomposition removal layer decomposed and removed in the abovementioned process, the pixel part forming ink 12 is adhered using theink jet apparatus 11 (FIG. 15B). Thereby, the pixel parts 6 are formedin the every other part in the pixel part forming parts (FIG. 15C). Asto the pixel parts formed here, it is preferable that the pixel partsthemselves are liquid repellent to prevent ink coloring, by the ink jetapparatus, in the second operation on the pixel parts. Moreover, thesurface thereof may be processed by an ink repellent processing agentsuch as a silicone compound and a fluorine containing compound.

Then, by irradiating the energy 10 again from the photocatalystcontaining layer side substrate 21 side with the decomposition removallayer 3, with the pixel parts formed in the every other part, and thephotocatalyst layer 23 placed with a certain gap similarly to the abovementioned, the decomposition removal layer 3 in the pixel part formingparts which have not been decomposed and removed in the above mentionedprocess are decomposed and removed (FIG. 15C). Thereby, the pixel partforming ink 12 is adhered to the pixel part forming parts 5 provided asthe lyophilic area by baring the transparent base material by thedecomposition of the decomposition removal layer, using the ink jetapparatus 11 similarly to the above mentioned so that a color filter canbe obtained (FIG. 15D).

According to the method, since the distance between the pixel parts canbe reduced or removed, a coloring layer (assembly of the pixel parts)having the excellent flatness can be formed. Moreover, since theinterval between the pixel parts to be formed at the time of the firstpixel part formation is wide, the inks cannot be mixed beyond the parts.Therefore, a high quality color filter without the ink color mixture orthe like can be obtained.

Although the pixel parts 6 formed in the first formation is in the everyother part in the above mentioned method, the present invention is notlimited thereto, and as long as the pixel parts formed initially are notprovided adjacently, it may be changed depending on the shape of thepixel parts of the color filter, such as the zigzag shape. Moreover,although the pixel parts are formed in two times of operations in theabove mentioned explanation, the pixel parts may be formed by three ormore times of operations, as needed.

(Liquid Repellent Convex Part)

In this embodiment, the process of forming the liquid repellent convexpart energy irradiating part by irradiating the energy to thephotocatalyst containing layer on the light shielding part, and formingthe liquid repellent convex part in the liquid repellent convex partenergy irradiating part may be provided after the decomposition removallayer forming process.

An example of the process for forming the liquid repellent convex partwill be explained using FIGS. 16A, 16B, 16C, 16D, and 16E. Similarly tothe above mentioned seventh embodiment shown in FIGS. 14A, 14B, 14C,14D, and 14E, the light shielding part 2 is formed on the transparentbase material 1, and the decomposition removal layer 3 is formed so asto cover the same. With the decomposition removal layer 3 and thephotocatalyst containing layer 23 of the photocatalyst containing layerside substrate 21 placed with a certain gap therebetween, the energy 10is irradiated using the photomask 24 in a pattern for forming the liquidrepellent convex part on the light shielding part 2 (FIG. 16A). Here, itis preferable that the contact angle to a liquid of the decompositionremoval layer 3 is larger than the contact angle to a liquid of thelight shielding part. Thereby, the liquid repellent convex part formingpart 7 with the decomposition removal layer 3 decomposed and removed canbe provided as the lyophilic area so that the liquid repellent convexpart forming ink 8 such as the UV curing type resin monomer can beadhered easily by the ink jet apparatus 11 (FIG. 16B). The coatingmethod for the liquid repellent convex part ink is not limited to themethod by the ink jet apparatus, and for example, other methods such asdip coating can be used as well.

Then, by curing the liquid repellent convex part forming ink 8 by the UVirradiation or the like, the liquid repellent convex part 9 is formed onthe light shielding part 2 (FIG. 16C). It is preferable that the widthof the liquid repellent convex part 9 is formed narrower than the widthof the light shielding part 2 as shown in the figure. By accordinglyforming, since the width of the pixel part to be formed in the processdescribed later can be made wider than the width of the opening partformed by the light shielding part, the problem of the color omission,or the like are not generated as mentioned above.

By placing the decomposition removal layer 3 with the liquid repellentconvex part 9 formed accordingly and the photocatalyst containing layer23 of the photocatalyst containing layer side substrate 21 with acertain gap therebetween, and irradiating the energy 10 to the entiresurface or in a pattern from the photocatalyst containing substrate 21side, the portion without the liquid repellent convex part 9 formed isirradiated with the energy so that the decomposition removal layer 3 isdecomposed and removed so as to form the pixel part forming part 5 ofthe lyophilic area with the transparent base material 1 bared (FIG.16C). Thereafter, similarly to the above mentioned method, by adheringthe pixel part forming ink 12 to the pixel part forming part provided asthe lyophilic area using the ink jet apparatus 11 and by curing, thepixel part 6 is formed so that a color filter provided with the liquidrepellent convex part 9 can be manufactured (FIGS. 16D and 16E).

Moreover, according to the liquid repellent convex part, by contactingthe liquid repellent convex part and the photocatalyst containing layerat the time of irradiating the energy using the photocatalyst containinglayer side substrate to provide the above mentioned pixel part formingpart as the lyophilic area, the liquid repellent convex part can act asa spacer for maintaining a certain gap.

Although the liquid repellent convex part is formed by the decompositionand removal of the photocatalyst containing layer in this embodiment,the present invention is not limited thereto, and for example, theliquid repellent convex part may be provided by the photolithographymethod or the like.

8. Eighth Embodiment

The eighth embodiment of the present invention is a method formanufacturing a color filter comprising:

(1) forming a decomposition removal layer, on the a transparent basematerial, having a higher contact angle to a liquid than the transparentbase material surface and is decomposed and removed by the function of aphotocatalyst;(2) placing the decomposition remocal layer and a photocatalystcontaining layer of a photocatalyst containing layer side substrate,which is the photocatalyst containing layer containing a photocatalystformed on a base member, with a gap of 200 μm or less, and irradiatingan energy from a predetermined direction to form a light shielding partforming part, in a pattern, comprising the transparent base materialbared by the decomposition removal of the decomposition removal layer;(3) forming a light shielding part in the light shielding part F formingpart;(4) placing the decomposition removal layer with the light shieldingpart formed thereon, and the photocatalyst containing layer with a gapof 200 μm or less, and irradiating an energy from a predetermineddirection to form a pixel part forming part, in a pattern, comprisingthe transparent base material bared by the decomposition removal of thedecomposition removal layer; and(5) coloring the pixel part forming part by an ink jet method so as toform a pixel part.

In this embodiment, as shown in FIGS. 17A, 17B, 17C, 17D, 17E, and 17Ffor example, the decomposition removal layer 3 is first formed on theentire surface of the transparent base material 1 (FIG. 17A). Next, withthe photocatalyst containing layer 23 formed on the base member 22 ofthe photocatalyst containing layer side substrate 21 placed with acertain gap to the decomposition removal layer 3, the energy 10 isirradiated in a pattern to the light shielding part forming part usingthe photomask 24 (FIG. 17B). By the energy irradiation, thedecomposition removal layer 3 in the light shielding part forming partis decomposed and removed so that the light shielding part 2 is formedon the lyophilic area with the transparent base material 1 bared (FIG.17C). Next, with the decomposition removal layer 3 with the lightshielding part formed and the photocatalyst containing layer 23 formedon the base member 22 of the photocatalyst containing layer sidesubstrate 21 placed with a certain gap therebetween, the energy 10 isirradiated (FIG. 17D). Thereby, the decomposition removal layer 3 of thepixel part forming part 5 is decomposed and removed so that thelyophilic area with the transparent base material 1 bared is provided.By coloring the pixel part forming part 5 provided as the lyophilic areawith the pixel part forming ink 12 by the ink jet apparatus 11 (FIG.17E), the pixel part 6 is formed (FIG. 17F). Hereafter, each processwill be explained.

(Decomposition Removal Layer Forming Process)

First, the decomposition removal layer 3 is formed on the entire surfaceof the transparent base material 1 (FIG. 17A. Since the transparent basematerial and the decomposition removal layer used here are same as thosein the seventh embodiment, explanation is omitted here.

(Process for Forming a Light Shielding Part Forming Part Comprising aLyophilic Area in a Pattern)

Next, similarly to the first embodiment, the photocatalyst containinglayer side substrate 21 is prepared. With the photocatalyst containinglayer 23 of the photocatalyst containing layer side substrate 21 placedwith a gap to the decomposition removal layer 3, the energy 10 isirradiated, using the photomask 24, to only the light shielding partforming part (FIG. 17B). By the energy irradiation, the decompositionremoval layer 3 provided on the light shielding part forming part isdecomposed and removed. At the time, the pixel part forming part is notirradiated with the energy, and thus it is the liquid repellent areawith the decomposition removal layer remaining. In this embodiment,pattern formation is carried out utilizing the liquid repellent propertydifference according to the existence and absence of the decompositionremoval layer. The photocatalyst containing layer side substrate used inthis embodiment is not particularly limited as long as only the lightshielding part is irradiated with the energy in a pattern as mentionedin the first embodiment, and one using a photomask, one with thephotocatalyst containing layer formed in a pattern, and one having thephotocatalyst containing layer and the light shielding part can be usedas well.

Since the photocatalyst containing layer side substrate and the energyirradiating process used in this embodiment are same as those in thefirst embodiment, explanation is omitted here.

(Light Shielding Part Forming Process)

Next, the light shielding part 2 is formed in the light shielding partforming part provided as the lyophilic area in the above mentionedprocess by the ink jet method or the like (FIG. 17C). In this case,since the pixel part forming part not provided as the lyophilic area isliquid repellent as mentioned above, the light shielding part paint isnot adhered onto the decomposition removal layer having the liquidrepellent property so that the light shielding part can be formed easilyby the ink jet method or the like.

Here, the light shielding part forming method of this embodiment is notlimited to the above mentioned ink jet method, and it may be thephotolithography method or the like.

Since the light shielding part material or the like in this embodimentis same as that in the first embodiment, explanation is omitted here.

(Process for Forming a Pixel Part Forming Part Comprising a LyophilicArea in a Pattern)

Next, similarly to the process for forming the light shielding partforming part in a pattern, the decomposition removal layer for the colorfilter substrate with the light shielding part formed in the abovementioned process, with the photocatalyst containing layer 23 of thephotocatalyst containing layer side substrate 21 and the decompositionremoval layer 3 placed with a gap therebetween, the energy 10 isirradiated to the pixel part forming part (FIG. 17D). By the energyirradiation, the decomposition removal layer 3 provided on the pixelpart forming part 5 is decomposed and removed so as to be formed as thelyophilic area. The energy irradiation in this case may be carried outin a pattern or to the entire surface.

Here, in this embodiment, according to the above mentioned energyirradiation, not only the decomposition removal layer in the pixel partforming part can be decomposed and removed but also the impurities onthe color filter generated in the above mentioned light shielding partforming process can be removed at the same time. In the case the abovementioned light shielding part is formed for example by thephotolithography method, a cleaning process is generally needed afterthe light shielding part formation, and it is carried out by the methodsuch as the irradiation of the UV including a low pressure mercury lamp,an excimer lamp, or the like to the entire surface. However, in thisembodiment, since the organic substances on the color filter substratecan also be decomposed by irradiating the energy, using the abovementioned photocatalyst containing layer side substrate, the cleaningprocess is not necessary, and thus it is preferable also in terms of theproduction efficiency and the cost.

The process for forming the pixel part forming part in a pattern in thisembodiment is same as that in the first embodiment, explanation isomitted here.

(Pixel Part Forming Process)

Furthermore, by adhering the pixel part forming ink 12 to the pixel partforming part 5 provided as the lyophilic area by the decomposition andremoval of the decomposition removal layer by the energy irradiation inthe above mentioned process by the ink jet apparatus 11, the pixel partis formed (FIGS. 17E and 17F). Since the pixel part forming process inthis embodiment is same as that in the first embodiment, explanation isomitted here.

9. Ninth Embodiment

The ninth embodiment of the present invention is a method formanufacturing a color filter comprising:

(1) forming a decomposition removal layer, on the a transparent basematerial, having a higher contact angle to a liquid than the transparentbase material surface and is decomposed and removed by the function of aphotocatalyst;(2) placing the decomposition remocal layer and a photocatalystcontaining layer of a photocatalyst containing layer side substrate,which is the photocatalyst containing layer containing a photocatalystformed on a base member, with a gap of 200 μm or less, and irradiatingan energy from a predetermined direction to form a pixel part formingpart, in a pattern, comprising the transparent base material bared bythe decomposition removal of the decomposition removal layer;(3) coloring the pixel part forming part by the ink jet method so as toform a pixel part;(4) placing the decomposition removal layer with the pixel part formedthereon, and the photocatalyst containing layer with a gap of 200 μm orless, and irradiating an energy from a predetermined direction to form alight shielding part forming part, in a pattern, comprising thetransparent base material bared by the decomposition removal of thedecomposition removal layer; and(5) forming a light shielding part in the light shielding part formingpart.

In this embodiment, as shown in FIGS. 18A, 18B, 18C, 18D, and 18E forexample, the decomposition removal layer 3 is formed on the transparentbase material 1 (FIG. 18A). Next, with the photocatalyst containinglayer 23 formed on the base member 22 of the photocatalyst containinglayer side substrate 21 placed with a certain gap to the decompositionremoval layer 3, the energy is irradiated to the pixel part forming partin a pattern using the photomask 24 (FIG. 18B). By the energyirradiation, the decomposition removal layer 3 of the pixel part formingpart is decomposed and removed so as to provide the lyophilic area withthe transparent base material 1 bared. By coloring the pixel partforming part provided as the lyophilic area by the decomposition andremoval of the decomposition removal layer, with the pixel part formingink 12, by the ink jet apparatus 11 (FIG. 18C), the pixel part 6 isformed. With the decomposition removal layer 3 with the pixel partformed and the photocatalyst containing layer 23 formed on the basemember 22 of the photocatalyst containing layer side substrate 21 placedwith a certain gap therebetween similarly to the above mentioned, theenergy 10 is irradiated (FIG. 18D) to decompose and remove thedecomposition removal layer of the light shielding part forming part.The light shielding part 2 is formed on the light shielding part formingpart 13 which the decomposition removal layer are decomposed and removed(FIG. 18E). Hereafter, each process will be explained.

(Decomposition Removal Layer Forming Process)

First, the decomposition removal layer 3 is formed on the entire surfaceof the transparent base material 1 (FIG. 18A). Since the transparentbase material and the decomposition removal layer used here are same asthose in the seventh embodiment, explanation is omitted here.

(Process for Forming a Pixel Part Forming Part Comprising a LyophilicArea in a Pattern)

Next, similarly to the first embodiment, the photocatalyst containinglayer side substrate 21 is prepared. With the photocatalyst containinglayer 23 of the photocatalyst containing layer side substrate 21 placedwith a gap to the decomposition removal layer 3, the energy 10 isirradiated to only the pixel part forming part using the photomask 24(FIG. 18B). By the energy irradiation, the decomposition removal layerprovided on the pixel part forming part is decomposed and removed. Atthe time, the light shielding part forming part is not irradiated withthe energy so that it is provided as the liquid repellent area. In thisembodiment, pattern formation is carried out utilizing the liquidrepellent property difference according to the existence and absence ofthe decomposition removal layer. The photocatalyst containing layer sidesubstrate used in this embodiment is not particularly limited as long asonly the pixel part forming part is irradiated with the energy in apattern as mentioned in the first embodiment, and one using a photomask,one with the photocatalyst containing layer formed in a pattern, and onehaving the photocatalyst containing layer and the light shielding partcan be used as well.

Since the photocatalyst containing layer side substrate and the energyirradiating process used in this embodiment are same as those in thefirst embodiment, explanation is omitted here.

(Pixel Part Forming Process)

Next, the pixel part is formed in the pixel part forming part providedas the lyophilic area formed in the above mentioned process for formingthe pixel part forming part comprising the lyophilic area in a patternby the ink jet method (FIG. 18C). In this case, since the lightshielding part forming part is liquid repellent as mentioned above, thepixel part can be formed easily by the ink jet method or the like. Sincethe pixel part forming process in this embodiment is same as that in thefirst embodiment, explanation is omitted here.

Moreover, in this embodiment, the formation method of executing theenergy irradiation and the pixel part formation divided in two or moretimes as explained in the above mentioned first embodiment may be usedbecause the inks may be mixed due to the narrow liquid repellent areabetween the pixel parts at the time of forming the pixel parts.

(Process for Forming a Light Shielding Part Forming Part Comprising aLyophilic Area in a Pattern)

Next, similarly to the process for forming the pixel part forming partin a pattern, with the decomposition removal layer 3 for the colorfilter substrate with the pixel part formed in the above mentionedprocess and the photocatalyst containing layer 23 of the photocatalystcontaining layer side substrate 21 placed with a gap therebetween, theenergy 10 is irradiated to the light shielding part forming part (FIG.18D). By the energy irradiation, the decomposition removal layer 3provided on the light shielding part forming part 13 is decomposed andremoved so as to form the lyophilic area. Since the energy irradiatingprocess for forming the light shielding part forming part in a patternin this embodiment is same as that in the first embodiment, explanationis omitted here.

(Light Shielding Part Forming Process)

Next, the light shielding part 2 is formed in the light shielding partforming part 13 provided as the lyophilic area in the above mentionedprocess by the ink jet method or the like (FIG. 18E). Since the lightshielding part forming process in this embodiment is same as that in theeighth embodiment, explanation is omitted here.

10. Others

In the above mentioned embodiments of the methods for manufacturing acolor filter, a protecting layer forming process or a process forforming other necessary functional layers may be executed.

B. Color Filter

Next, a color filter of the present invention will be explained.

The color filter of the present invention is comprising a transparentbase material, a pixel part with a plurality of colors provided in apredetermined pattern on the transparent base material by the ink jetmethod, a light shielding part provided in the pixel part boundary part,and a decomposition removal layer to be decomposed and removed by aphotocatalyst provided for forming the above mentioned pixel part or theabove mentioned light shielding part.

In the color filter of the present invention, as shown in FIG. 19 forexample, comprises the pixel part 6 with a plurality of colors providedin a predetermined pattern on the transparent base material 1 by theejecting method, the light shielding part 2 provided in the pixel partboundary part, and the decomposition removal layer 3 to be decomposedand removed by the function of the photocatalyst on the light shieldingpart.

Since the decomposition removal layer having a contact angle to a liquidlarger than that on the transparent base material is formed on the abovementioned light shielding part, the ink color mixture or the like can beprevented at the time of forming the pixel part so that a color filterhaving a highly sophisticated pattern can be provided, and thus it isadvantageous.

Since the transparent base material, the pixel part, the light shieldingpart, the decomposition removal layer, and the manufacturing method ofthe color filter can be formed using the above mentioned seventhembodiment, explanation is omitted here.

C. Color Liquid Crystal Display

In the present invention, a color liquid crystal display is formed byusing the color filter of any of the above mentioned first to ninthembodiments, combining with a facing substrate facing to the colorfilter, and sealing a liquid crystal compound therebetween. The colorliquid crystal display accordingly obtained has the advantages of thecolor filter of the present invention, that is, without the coloromission or the color fading, and the advantage in terms of the cost.

The present invention is not limited to the above mentioned embodiments.The above mentioned embodiments are merely examples, and any one havingthe substantially same configuration as the technological idea disclosedin the claims of the present invention and the same effects is includedin the technological scope of the present invention.

For example, in the above mentioned explanation for the method formanufacturing a color filter, and the color filter, although only theexample of the contact angle to a liquid of the decomposition removallayer larger than the contact angle to a liquid of the transparent basematerial has been explained, the contact angle to a liquid of thedecomposition removal layer may be smaller than the contact angle to aliquid of the transparent base material. In this case, the area with thedecomposition removal layer decomposed and removed is provided as theliquid repellent area, and the area with the decomposition removal layerremaining is provided as the lyophilic area. Thereby, for example,formation of the pixel part by the ink jet method is carried out on thelyophilic area on the decomposition removal layer.

EXAMPLES

Hereinafter, the present invention will be explained in further detailswith reference to the examples.

Example 1 1. Formation of the Photocatalyst Containing Layer SideSubstrate

5 g of a trimethoxy methyl silane (TSL8113, manufactured by GE ToshibaSilicones Co., Ltd.) and 2.5 g of a 0.5 normal hydrochloric acid weremixed, and agitated for 8 hours. The same was diluted by an isopropylalcohol to 10 times so as to provide a primer layer composition.

By coating the above mentioned primer layer composition onto a photomasksubstrate by a spin coater, and executing a drying process at 150° C.for 10 minutes, a transparent primer layer (thickness 0.2 μm) wasformed.

Next, 30 g of an isopropyl alcohol, 3 g of a trimethoxy methyl silane(TSL8113, manufactured by GE Toshiba Silicones Co., Ltd.), and 20 g ofST-K03 (manufactured by Ishihara Sangyo Kaisha, Ltd.) as a photocatalystinorganic coating agent were mixed and agitated at 100° C. for 20minutes. The same was diluted by an isopropyl alcohol to 3 times so asto provide a photocatalyst containing layer composition.

By coating the above mentioned photocatalyst containing layercomposition on the photomask substrate with the primer layer formed by aspin coater, and executing a drying process at 150° C. for 10 minutes, atransparent photocatalyst containing layer (thickness 0.15 μm) wasformed.

2. Formation of the Wettability Changeable Layer

30 g of an isopropyl alcohol, 0.4 g of a fluoro alkyl silane(manufactured by GE Toshiba Silicones Co., Ltd.), 3 g of a trimethoxymethyl silane (TSL8113, GE Toshiba Silicones Co., Ltd.), and 2.5 g of a0.5 normal hydrochloric acid were mixed and agitated for 8 hours. Thesame was diluted by an isopropyl alcohol to 100 times so as to provide awettability changeable layer composition.

By coating the above mentioned wettability changeable layer compositionon the transparent substrate with the light shielding layer formed by aspin coater, and executing a drying process at 150° C. for 10 minutes, atransparent wettability changeable layer (thickness 0.1 μm) was formed.

3. Confirmation of the Lyophilic Area Formation by Exposure

The aligned photocatalyst containing layer side substrate and thewettability changeable layer were faced with each other with a 100 μmgap therebetween, exposed by a 40 mW/cm² illuminance by an extra highpressure mercury lamp (wavelength 365 nm) from the photomask side for 60seconds so as to form a pixel part forming part comprising the lyophilicarea on the wettability changeable layer in a pattern.

At the time, the contact angles of the unexposed part and the pixel partforming part to a wetting index standard solution of 40 mN/m surfacetension (manufactured by Junsei Chemical, Co., Ltd.) was measured (30seconds after dropping liquid droplets form a micro syringe) using acontact angle measuring device (CA-Z type manufactured by KyowaInterface Science, Co., Ltd.) and they were 70°, and 7°, respectively.

4. Formation of the Pixel Part

Next, using the ink jet apparatus, UV curing type polyfunctionalacrylate monomer inks of each RGB colors containing 5 parts by weight ofa pigment, 20 parts by weight of a solvent, 5 parts by weight of apolymerization initiating agent, and 70 parts by weight of a UV curingresin were adhered on the pixel part exposing part provided as lyophilicon the transparent substrate for coloring, and the UV process wasexecuted thereto for curing. For the red, green and blue inks, as thesolvent, a polyethylene glycol monomethyl ethyl acetate, as thepolymerization initiating agent, IRUGACURE 369 (product name,manufactured by Chiba Specialty Chemicals), and as the UV curing resin,a DPHA (dipenta erythritol hexaacrylate (manufactured by NIPPON KAYAKUCO., LTD.) were used. Moreover, as the pigment, for the red ink, C. I.Pigment Red 177, for the green ink, C. I. Pigment Green 36, and for theblue ink, C. I. Pigment Blue 15+C. I. Pigment Violet 23 were used,respectively.

5. Formation of the Protecting Layer

As the protecting layer, a two liquid mixing type thermosetting agent(manufactured by Nippon Gosei Gomu Co., SS7265) was coated by a spincoater. By carrying out curing process at 200° C. for 30 minutes, aprotecting layer was formed so as to obtain a color filter. The obtainedcolor filter was of a high quality without the color omission or thecolor irregularity in the pixel part.

Example 2 1. Formation of the Photocatalyst Containing Layer SideSubstrate

5 g of a trimethoxy methyl silane (TSL8113, manufactured by GE ToshibaSilicones Co., Ltd.) and 2.5 g of a 0.5 normal hydrochloric acid weremixed, and agitated for 8 hours. The same was diluted by an isopropylalcohol to 10 times so as to provide a primer layer composition.

By coating the above mentioned primer layer composition onto a photomasksubstrate by a spin coater, and executing a drying process at 150° C.for 10 minutes, a transparent primer layer (thickness 0.2 μm) wasformed.

Next, 30 g of an isopropyl alcohol, 3 g of a trimethoxy methyl silane(TSL8113, manufactured by GE Toshiba Silicones Co., Ltd.), and 20 g ofST-K03 (manufactured by Ishihara Sangyo Kaisha, Ltd.) as a photocatalystinorganic coating agent were mixed and agitated at 100° C. for 20minutes. The same was diluted by an isopropyl alcohol to 3 times so asto provide a photocatalyst containing layer composition.

By coating the above mentioned photocatalyst containing layercomposition on the photomask substrate with the primer layer formed by aspin coater, and executing a drying process at 150° C. for 10 minutes, atransparent photocatalyst containing layer (thickness 0.15 μm) wasformed.

2. Formation of the Decomposition Removal Layer

2 g of EUPIRON Z400 (manufactured by Mitsubishi Gas Chemical Company,Inc.) containing a polycarbonate as the main component was dissolvedinto 30 g of a dichloro methane and 70 g of a 112 trichloro ethane so asto provide a decomposition layer removal layer composition.

By coating the above mentioned decomposition removal layer compound onthe glass substrate with the light shielding layer formed by a spincoater, and executing a drying process at 100° C. for 60 minutes, atransparent wettability changeable layer (thickness 0.01 μm) was formed.

3. Formation of the Pixel Part Forming Part by the Exposure

The aligned photocatalyst containing layer side substrate and thedecomposition remocal layer were faced with each other with a 100 μm gaptherebetween, exposed by a 40 mW/cm² illuminance by an extra highpressure mercury lamp (wavelength 365 nm) from the photomask side for600 seconds so as to decompose and remove the decomposition removallayer and form a pixel part forming part comprising the bared glasssubstrate in a pattern.

At the time, the contact angles of the unexposed part and the pixel partforming part to a wetting index standard solution of 40 mN/m surfacetension (manufactured by Junsei Chemical, Co., Ltd.) was measured (30seconds after dropping liquid droplets form a micro syringe) using acontact angle measuring device (CA-Z type manufactured by KyowaInterface Science, Co., Ltd.), and they were 490, and 60, respectively.

4. Formation of the Pixel Part

Next, using the ink jet apparatus, UV curing type polyfunctionalacrylate monomer inks of each RGB colors containing 5 parts by weight ofa pigment, 20 parts by weight of a solvent, 5 parts by weight of apolymerization initiating agent, and 70 parts by weight of a UV curingresin were adhered on the pixel part forming part for coloring, and theUV process was executed thereto for curing. For the red, green and blueinks, as the solvent, a polyethylene glycol monomethyl ethyl acetate, asthe polymerization initiating agent, IRUGACURE 369 (product name,manufactured by Chiba Specialty Chemicals), and as the UV curing resin,a DPHA (dipenta erythritol hexaacrylate (manufactured by NIPPON KAYAKUCO., LTD.) were used. Moreover, as the pigment, for the red ink, C. I.Pigment Red 177, for the green ink, C. I. Pigment Green 36, and for theblue ink, C. I. Pigment Blue 15+C. I. Pigment Violet 23 were used,respectively.

5. Formation of the Protecting Layer

As the protecting layer, a two liquid mixing type thermosetting agent(manufactured by Nippon Gosei Gomu Co., SS7265) was coated by a spincoater. By carrying out the curing process at 200° C. for 30 minutes, aprotecting layer was formed so as to obtain a color filter. The obtainedcolor filter was of a high quality without the color omission or thecolor irregularity in the pixel part.

Example 3 1. Formation of the Photocatalyst Containing Layer SideSubstrate

5 g of a trimethoxy methyl silane (TSL113, manufactured by GE ToshibaSilicones Co., Ltd.) and 2.5 g of a 0.5 normal hydrochloric acid weremixed, and agitated for 8 hours. The same was diluted by an isopropylalcohol to 10 times so as to provide a primer layer composition.

By coating the above mentioned primer layer composition onto a photomasksubstrate by a spin coater, and executing a drying process at 150° C.for 10 minutes, a transparent primer layer (thickness 0.2 μm) wasformed.

Next, 30 g of an isopropyl alcohol, 3 g of a trimethoxy methylsilane(TSL8113, manufactured by GE Toshiba Silicones Co., Ltd.), and 20 g ofST-K03 (manufactured by Ishihara Sangyo Kaisha, Ltd.) as a photocatalystinorganic coating agent were mixed and agitated at 100° C. for 20minutes. The same was diluted by an isopropyl alcohol to 3 times so asto provide a photocatalyst containing layer composition.

By coating the above mentioned photocatalyst containing layercomposition on the photomask substrate with the primer layer formed by aspin coater, and executing a drying process at 150° C. for 10 minutes, atransparent photocatalyst containing layer (thickness 0.15 μm) wasformed.

2. Formation of the Decomposition Removal Layer

A polydiallyl dimethyl ammonium chloride (PDDA, average molecular weight100,000 to 200,000, ARUDORICCHI) as a cationic polymer, and a sodiumpolystyrene sulfonate (PSS, average molecular weight 70,000,ARUDORICCHI) as an anionic polymer were assembled layer by layer on aglass base material by about a 2 nm thickness.

3. Formation of the Pixel Part Forming Part by the Exposure

The aligned photocatalyst containing layer side substrate and thedecomposition removal layer were faced with each other with a 50 μm gaptherebetween, exposed by a 40 mW/cm² illuminance by an extra highpressure mercury lamp (wavelength 365 nm) from the photomask side for120 seconds so as to decompose and remove the decomposition removallayer and formed a pixel part forming part comprising the bared glasssubstrate in a pattern.

At the time, the contact angles of the unexposed part and the pixel partforming part to a wetting index standard solution of 40 mN/m surfacetension (manufactured by Junsei Chemical, Co., Ltd.) was measured (30seconds after dropping liquid droplets form a micro syringe) using acontact angle measuring device (CA-Z type manufactured by KyowaInterface Science, Co., Ltd.), and they were 30°, and 6°, respectively.

4. Formation of the Pixel Part

Next, using the ink jet apparatus, UV curing type polyfunctionalacrylate monomer inks of each RGB colors containing 5 parts by weight ofa pigment, 20 parts by weight of a solvent, 5 parts by weight of apolymerization initiating agent, and 70 parts by weight of a UV curingresin were adhered on the pixel part forming part for coloring, and theUV process was executed thereto for curing. For the red, green and blueinks, as the solvent, a polyethylene glycol monomethyl ethyl acetate, asthe polymerization initiating agent, IRUGACURE 369 (product name,manufactured by Chiba Specialty Chemicals), and as the UV curing resin,a DPHA (dipenta erythritol hexaacrylate (manufactured by NIPPON KAYAKUCO., LTD.) were used. Moreover, as the pigment, for the red ink, C. I.Pigment Red 177, for the green ink, C. I. Pigment Green 36, and for theblue ink, C. I. Pigment Blue 15+C. I. Pigment Violet 23 were used,respectively.

5. Formation of the Protecting Layer

As the protecting layer, a two liquid mixing type thermosetting agent(manufactured by Nippon Gosei Gomu Co., SS7265) was coated by a spincoater. By carrying out the curing process at 200° C. for 30 minutes, aprotecting layer was formed so as to obtain a color filter. The obtainedcolor filter was of a high quality without the color omission or thecolor irregularity in the pixel part.

Example 4 1. Formation of the Photocatalyst Containing Layer SideSubstrate

5 g of a trimethoxy methyl silane (TSL8113, manufactured by GE ToshibaSilicones Co., Ltd.) and 2.5 g of a 0.5 normal hydrochloric acid weremixed, and agitated for 8 hours. The same was diluted by an isopropylalcohol to 10 times so as to provide a primer layer composition.

By coating the above mentioned primer layer composition onto a photomasksubstrate by a spin coater, and executing a drying process at 150° C.for 10 minutes, a transparent primer layer (thickness 0.2 μm) wasformed.

Next, 30 g of an isopropyl alcohol, 3 g of a trimethoxy methyl silane(TSL8113, manufactured by GE Toshiba Silicones Co., Ltd.), and 20 g ofST-K03 (manufactured by Ishihara Sangyo Kaisha, Ltd.) as a photocatalystinorganic coating agent were mixed and agitated at 100° C. for 20minutes. The same was diluted by an isopropyl alcohol to 3 times so asto provide a photocatalyst containing layer composition.

By coating the above mentioned photocatalyst containing layercomposition on the photomask substrate with the primer layer formed by aspin coater, and executing a drying process at 150° C. for 10 minutes, atransparent photocatalyst containing layer (thickness 0.15 μm) wasformed.

2. Formation of the Decomposition Removal Layer

1 g of TEFLON AF 1600 (manufactured by Du Pont) was dissolved in 200 gof FLUORINERT FC-43 (produced by Sumitomo 3M) so as to provide adecomposition removal layer composition.

By coating the above mentioned decomposition removal layer compound onthe glass substrate with the light shielding layer formed by a spincoater, and executing a drying process at 100° C. for 60 minutes, atransparent wettability changeable layer (thickness 0.01 μm) was formed.

3. Formation of the Pixel Part Forming Part by the Exposure

The aligned photocatalyst containing layer side substrate and thedecomposition removal layer were faced with each other with a 100 μm gaptherebetween, exposed by a 40 mW/cm² illuminance by an extra highpressure mercury lamp (wavelength 365 nm) from the photomask side for1,800 seconds so as to decompose and remove the decomposition removallayer and formed a pixel part forming part comprising the bared glasssubstrate in a pattern.

At the time, the contact angles of the unexposed part and the pixel partforming part to a wetting index standard solution of 40 mN/m surfacetension (manufactured by Junsei Chemical, Co., Ltd.) was measured (30seconds after dropping liquid droplets form a micro syringe) using acontact angle measuring device (CA-Z type manufactured by KyowaInterface Science, Co., Ltd.), and they were 74°, and 6°, respectively.

4. Formation of the Pixel Part

Next, using the ink jet apparatus, UV curing type polyfunctionalacrylate monomer inks of each RGB colors containing 5 parts by weight ofa pigment, 20 parts by weight of a solvent, 5 parts by weight of apolymerization initiating agent, and 70 parts by weight of a UV curingresin were adhered on the pixel part forming part for coloring, and theUV process was carried out for curing. For the red, green and blue inks,as the solvent, a polyethylene glycol monomethyl ethyl acetate, as thepolymerization initiating agent, IRUGACURE 369 (product name,manufactured by Chiba Specialty Chemicals), and as the UV curing resin,a DPHA (dipenta erythritol hexaacrylate (manufactured by NIPPON KAYAKUCO., LTD.) were used. Moreover, as the pigment, for the red ink, C. I.Pigment Red 177, for the green ink, C. I. Pigment Green 36, and for theblue ink, C. I. Pigment Blue 15+C. I. Pigment Violet 23 were used,respectively.

5. Formation of the Protecting Layer

As the protection layer, a two liquid mixing type thermosetting agent(manufactured by Nippon Gosei Gomu Co., SS7265) was coated by a spincoater. By carrying out the curing process at 200° C. for 30 minutes, aprotecting layer was formed so as to obtain a color filter. The obtainedcolor filter was of a high quality without the color omission or thecolor irregularity in the pixel part.

1. A color filter comprising a transparent base material, a pixel partprovided on the transparent base material in a predetermined patternwith a plurality of colors by an ink jet method, a light shielding partprovided on the boundary part of the pixel part, and a decompositionremoval layer capable of being decomposed and removed by thephotocatalyst, provided for forming the pixel part or the lightshielding part.
 2. A color filter comprising a transparent basematerial, a pixel part provided on the transparent base material in apredetermined pattern with a plurality of colors by the ink jet method,a light shielding part provided on the boundary part of the pixel part,and a decomposition removal layer capable of being decomposed andremoved by the function of the photocatalyst formed on the lightshielding part.
 3. A liquid crystal display comprising a color filteraccording to claim 1, a substrate facing the same, and a liquid crystalcompound sealed in between the both substrates.
 4. A liquid crystaldisplay comprising a color filter according to claim 2, a substratefacing the same, and a liquid crystal compound sealed in between theboth substrates.